Aspen Plus Reference Manual, Unit Operation Models

Unit Operation Models
S T E A D Y S T A T E S I M U L A T I O N
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Uni t Operati on Model s i i i
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Contents
About the Unit Operation Models Reference Manual
For More I nformati on..............................................................................................................x
Techni cal Support ..................................................................................................................xi
1 Mixers and Splitters
Mi xer .....................................................................................................................................1-2
Fl owsheet Connecti vi ty for Mi xer ....................................................................................1-2
Speci fyi ng Mi xer ...............................................................................................................1-3
FSpl i t.....................................................................................................................................1-5
Fl owsheet Connecti vi ty for FSpl i t...................................................................................1-5
Speci fyi ng FSpl i t ...............................................................................................................1-6
SSpl i t.....................................................................................................................................1-8
Fl owsheet Connecti vi ty for SSpl i t ....................................................................................1-8
Speci fyi ng SSpl i t ...............................................................................................................1-8
2 Separators
Fl ash2....................................................................................................................................2-2
Fl owsheet Connecti vi ty for Fl ash2..................................................................................2-2
Speci fyi ng Fl ash2 .............................................................................................................2-3
Fl ash3....................................................................................................................................2-5
Fl owsheet Connecti vi ty for Fl ash3..................................................................................2-5
Speci fyi ng Fl ash3 .............................................................................................................2-6
Decanter ................................................................................................................................2-8
Fl owsheet Connecti vi ty for Decanter ..............................................................................2-8
Speci fyi ng Decanter .........................................................................................................2-9
Sep.......................................................................................................................................2-12
Fl owsheet Connecti vi ty for Sep ......................................................................................2-12
Speci fyi ng Sep .................................................................................................................2-13
Sep2.....................................................................................................................................2-14
Fl owsheet Connecti vi ty for Sep2 ....................................................................................2-14
Speci fyi ng Sep2...............................................................................................................2-15
3 Heat Exchangers
Heater ...................................................................................................................................3-2
Fl owsheet Connecti vi ty for Heater..................................................................................3-2
Speci fyi ng Heater .............................................................................................................3-3
HeatX ....................................................................................................................................3-5
Fl owsheet Connecti vi ty for HeatX...................................................................................3-5
Speci fyi ng HeatX..............................................................................................................3-6
References ...........................................................................................................................3-18
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MHeatX.............................................................................................................................. 3-19
Fl owsheet Connecti vi ty for MHeatX ............................................................................ 3-19
Speci fyi ng MHeatX........................................................................................................ 3-20
Hetran ................................................................................................................................ 3-23
Fl owsheet Connecti vi ty for Hetran .............................................................................. 3-23
Speci fyi ng Hetran .......................................................................................................... 3-24
Aerotran ............................................................................................................................. 3-26
Fl owsheet Connecti vi ty for Aerotran ........................................................................... 3-26
Speci fyi ng Aerotran ....................................................................................................... 3-27
4 Columns
DSTWU ................................................................................................................................ 4-3
Fl owsheet Connecti vi ty for DSTWU ................................................................................ 4-3
Speci fyi ng DSTWU........................................................................................................... 4-4
Di stl ...................................................................................................................................... 4-6
Fl owsheet Connecti vi ty for Di stl ...................................................................................... 4-6
Speci fyi ng Di stl ................................................................................................................ 4-7
SCFrac.................................................................................................................................. 4-8
Fl owsheet Connecti vi ty for SCFrac ................................................................................. 4-8
Speci fyi ng SCFrac............................................................................................................ 4-9
RadFrac.............................................................................................................................. 4-11
Fl owsheet Connecti vi ty for RadFrac............................................................................ 4-12
Speci fyi ng RadFrac........................................................................................................ 4-13
Free-Water and Ri gorous Three-Phase Cal cul ati ons .................................................. 4-20
Effi ci enci es ..................................................................................................................... 4-20
Al gori thms...................................................................................................................... 4-22
Rati ng Mode................................................................................................................... 4-23
Desi gn Mode................................................................................................................... 4-24
Reacti ve Di sti l l ati on ...................................................................................................... 4-25
Sol uti on Strategi es ........................................................................................................ 4-25
Physi cal Properti es ........................................................................................................ 4-28
Sol i ds Handl i ng ............................................................................................................. 4-28
Mul ti Frac ........................................................................................................................... 4-30
Fl owsheet Connecti vi ty for Mul ti Frac.......................................................................... 4-31
Speci fyi ng Mul ti Frac..................................................................................................... 4-33
Effi ci enci es ..................................................................................................................... 4-41
Al gori thms...................................................................................................................... 4-42
Rati ng Mode................................................................................................................... 4-42
Desi gn Mode................................................................................................................... 4-42
Col umn Convergence..................................................................................................... 4-43
Physi cal Properti es ........................................................................................................ 4-46
Free Water Handl i ng..................................................................................................... 4-46
Sol i ds Handl i ng ............................................................................................................. 4-46
Si zi ng and Rati ng of Trays and Packi ngs .................................................................... 4-47
PetroFrac............................................................................................................................ 4-48
Fl owsheet Connecti vi ty for PetroFrac.......................................................................... 4-49
Speci fyi ng PetroFrac...................................................................................................... 4-51
Effi ci enci es ..................................................................................................................... 4-57
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Convergence....................................................................................................................4-58
Rati ng Mode....................................................................................................................4-59
Desi gn Mode ...................................................................................................................4-59
Physi cal Properti es.........................................................................................................4-60
Free Water Handl i ng .....................................................................................................4-60
Sol i ds Handl i ng ..............................................................................................................4-61
Si zi ng and Rati ng of Trays and Packi ngs .....................................................................4-61
RateFrac..............................................................................................................................4-62
Fl owsheet Connecti vi ty for RateFrac............................................................................4-63
The Rate-Based Model i ng Concept................................................................................4-65
Speci fyi ng RateFrac .......................................................................................................4-66
Mass and Heat Transfer Correl ati ons...........................................................................4-77
References ...........................................................................................................................4-85
Extract ................................................................................................................................4-87
Fl owsheet Connecti vi ty for Extract...............................................................................4-87
Speci fyi ng Extract ..........................................................................................................4-88
5 Reactors
RStoi c....................................................................................................................................5-2
Fl owsheet Connecti vi ty for RStoi c ..................................................................................5-2
Speci fyi ng RStoi c..............................................................................................................5-3
RYi el d....................................................................................................................................5-6
Fl owsheet Connecti vi ty for RYi el d..................................................................................5-6
Speci fyi ng RYi el d .............................................................................................................5-7
REqui l ...................................................................................................................................5-8
Fl owsheet Connecti vi ty for REqui l ..................................................................................5-8
Speci fyi ng REqui l .............................................................................................................5-9
RGi bbs.................................................................................................................................5-10
Fl owsheet Connecti vi ty for RGi bbs ...............................................................................5-10
Speci fyi ng RGi bbs ..........................................................................................................5-11
References ...........................................................................................................................5-15
RCSTR ................................................................................................................................5-16
Fl owsheet Connecti vi ty for RCSTR...............................................................................5-16
Speci fyi ng RCSTR ..........................................................................................................5-17
RPl ug...................................................................................................................................5-21
Fl owsheet Connecti vi ty for RPl ug.................................................................................5-21
Speci fyi ng RPl ug ............................................................................................................5-22
RBatch ................................................................................................................................5-25
Fl owsheet Connecti vi ty for RBatch...............................................................................5-25
Speci fyi ng RBatch ..........................................................................................................5-26
6 Pressure Changers
Pump .....................................................................................................................................6-2
Fl owsheet Connecti vi ty for Pump ...................................................................................6-2
Speci fyi ng Pump ...............................................................................................................6-3
Compr ....................................................................................................................................6-9
Fl owsheet Connecti vi ty for Compr ..................................................................................6-9
Speci fyi ng Compr ............................................................................................................6-10
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MCompr .............................................................................................................................. 6-13
Fl owsheet Connecti vi ty for MCompr ............................................................................. 6-13
Speci fyi ng MCompr ........................................................................................................ 6-15
References .......................................................................................................................... 6-19
Val ve................................................................................................................................... 6-20
Fl owsheet Connecti vi ty for Val ve................................................................................. 6-20
Speci fyi ng Val ve ............................................................................................................ 6-20
References .......................................................................................................................... 6-29
Pi pe..................................................................................................................................... 6-30
Fl owsheet Connecti vi ty for Pi pe ................................................................................... 6-30
Speci fyi ng Pi pe .............................................................................................................. 6-31
Two-Phase Correl ati ons ................................................................................................ 6-35
Cl osed-Form Methods.................................................................................................... 6-39
References .......................................................................................................................... 6-40
Pi pel i ne .............................................................................................................................. 6-42
Fl owsheet Connecti vi ty for Pi pel i ne............................................................................. 6-42
Speci fyi ng Pi pel i ne ......................................................................................................... 6-43
Two-Phase Correl ati ons ................................................................................................ 6-47
Cl osed-Form Methods.................................................................................................... 6-50
References .......................................................................................................................... 6-52
7 Manipulators
Mul t ...................................................................................................................................... 7-2
Fl owsheet Connecti vi ty for Mul t...................................................................................... 7-2
Speci fyi ng Mul t................................................................................................................ 7-3
Dupl ...................................................................................................................................... 7-4
Fl owsheet Connecti vi ty for Dupl ...................................................................................... 7-4
Speci fyi ng Dupl ................................................................................................................ 7-5
Cl Chng ................................................................................................................................. 7-6
Fl owsheet Connecti vi ty for Cl Chng................................................................................ 7-6
Speci fyi ng Cl Chng............................................................................................................ 7-6
8 Solids
Crystal l i zer .......................................................................................................................... 8-3
Fl owsheet Connecti vi ty for Crystal l i zer .......................................................................... 8-3
Speci fyi ng Crystal l i zer ..................................................................................................... 8-4
References .......................................................................................................................... 8-11
Crusher ............................................................................................................................... 8-13
Fl owsheet Connecti vi ty for Crusher ............................................................................. 8-13
Speci fyi ng Crusher ........................................................................................................ 8-14
References .......................................................................................................................... 8-18
Screen ................................................................................................................................. 8-19
Fl owsheet Connecti vi ty for Screen ............................................................................... 8-19
Speci fyi ng Screen........................................................................................................... 8-19
References .......................................................................................................................... 8-22
FabFl .................................................................................................................................. 8-23
Fl owsheet Connecti vi ty for FabFl................................................................................. 8-23
Speci fyi ng FabFl ............................................................................................................. 8-23
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References ...........................................................................................................................8-26
Cycl one ................................................................................................................................8-27
Fl owsheet Connecti vi ty for Cycl one................................................................................8-27
Speci fyi ng Cycl one ..........................................................................................................8-28
References ...........................................................................................................................8-35
VScrub.................................................................................................................................8-36
Fl owsheet Connecti vi ty for VScrub ................................................................................8-36
Speci fyi ng VScrub ...........................................................................................................8-37
References ...........................................................................................................................8-39
ESP......................................................................................................................................8-40
Fl owsheet Connecti vi ty for ESP .....................................................................................8-40
Speci fyi ng ESP................................................................................................................8-41
References ...........................................................................................................................8-44
HyCyc..................................................................................................................................8-45
Fl owsheet Connecti vi ty for HyCyc..................................................................................8-45
Speci fyi ng HyCyc ............................................................................................................8-46
References ...........................................................................................................................8-51
CFuge ..................................................................................................................................8-52
Fl owsheet Connecti vi ty for CFuge ................................................................................8-52
Speci fyi ng CFuge............................................................................................................8-53
References ...........................................................................................................................8-55
Fi l ter ...................................................................................................................................8-56
Fl owsheet Confi gurati on for Fi l ter ................................................................................8-56
Speci fyi ng Fi l ter .............................................................................................................8-56
References ...........................................................................................................................8-59
SWash .................................................................................................................................8-61
Fl owsheet Connecti vi ty for SWash................................................................................8-61
Speci fyi ng SWash ...........................................................................................................8-62
CCD.....................................................................................................................................8-64
Fl owsheet Connecti vi ty for CCD...................................................................................8-64
Speci fyi ng CCD...............................................................................................................8-65
9 User Models
User .......................................................................................................................................9-2
Fl owsheet Connecti vi ty for User .....................................................................................9-2
Speci fyi ng User .................................................................................................................9-3
User2.....................................................................................................................................9-4
Fl owsheet Connecti vi ty for User2 ...................................................................................9-4
Speci fyi ng User2...............................................................................................................9-5
10 Pressure Relief
Pres-Rel i ef...........................................................................................................................10-2
Speci fyi ng Pres-Rel i ef ....................................................................................................10-2
Scenari os .........................................................................................................................10-3
Compl i ance wi th Codes ..................................................................................................10-6
Stream and Vessel Composi ti ons and Condi ti ons ........................................................10-6
Rul es to Si ze the Rel i ef Val ve Pi pi ng............................................................................10-7
Reacti ons .........................................................................................................................10-9
vi i i Uni t Operati on Model s
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Rel i ef System ............................................................................................................... 10-10
Data Tabl es for Pi pes and Rel i ef Devi ces................................................................... 10-12
Val ve Cycl i ng ............................................................................................................... 10-16
Vessel Types................................................................................................................. 10-16
Di sengagement Model s ............................................................................................... 10-18
Stop Cri teri a ................................................................................................................ 10-18
Sol uti on Procedure for Dynami c Scenari os................................................................ 10-19
Fl ow Equati ons ............................................................................................................ 10-20
Cal cul ati on and Convergence Methods ...................................................................... 10-23
Vessel I nsul ati on Credi t Factor .................................................................................. 10-24
References ........................................................................................................................ 10-25
A Sizing and Rating for Trays and Packings
Si ngl e-Pass and Mul ti -Pass Trays..................................................................................A-2
Modes of Operati on for Trays .........................................................................................A-8
Fl oodi ng Cal cul ati ons for Trays......................................................................................A-8
Bubbl e Cap Tray Layout .................................................................................................A-9
Pressure Drop Cal cul ati ons for Trays ..........................................................................A-10
Foami ng Cal cul ati ons for Trays ...................................................................................A-11
Packed Col umns ............................................................................................................A-12
Packi ng Types and Packi ng Factors.............................................................................A-12
Modes of Operati on for Packi ng....................................................................................A-12
Maxi mum Capaci ty Cal cul ati ons for Packi ng .............................................................A-13
Pressure Drop Cal cul ati ons for Packi ng ......................................................................A-15
Li qui d Hol dup Cal cul ati ons for Packi ng......................................................................A-16
Pressure Profi l e Update ................................................................................................A-17
Physi cal Property Data Requi rements .........................................................................A-17
References ..........................................................................................................................A-18
Index
Uni t Operati on Model s i x
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About the Unit Operation
Models Reference Manual
Vol ume 1 of the ASPEN PLUS Reference Manual s, Unit Operation Models,
i ncl udes detai l ed techni cal reference i nformati on for al l ASPEN PLUS uni t
operati on model s and the Pres-Rel i ef model . The i nformati on i n thi s manual i s
al so avai l abl e i n onl i ne hel p and prompts.
Model s are grouped i n chapters accordi ng to uni t operati on type. The reference
i nformati on for each model i ncl udes a descri pti on of the model and i ts typi cal
usage, a di agram of i ts fl owsheet connecti vi ty, a di scussi on of the speci fi cati ons
you must provi de for the model , i mportant equati ons and correl ati ons, and other
rel evant i nformati on.
An overvi ew of al l ASPEN PLUS uni t operati on model s, and general i nformati on
about the steps and procedures i n usi ng them i s i n the ASPEN PLUS User Guide
as wel l as i n the onl i ne hel p and prompts i n ASPEN PLUS.
x Uni t Operati on Model s
Versi on 10
For More Information
Onl i ne Hel p ASPEN PLUS has a compl ete system of onl i ne hel p and
context-sensi ti ve prompts. The hel p system contai ns both context-sensi ti ve hel p
and reference i nformati on. For more i nformati on about usi ng ASPEN PLUS hel p,
see the ASPEN PLUS User Guide, Chapter 3.
ASPEN PLUS Getti ng Started Bui l di ng and Runni ng a Process Model
Thi s tutori al i ncl udes several hands-on sessi ons to fami l i ari ze you wi th
ASPEN PLUS. The gui de takes you step-by-step to l earn the ful l power and scope
of ASPEN PLUS.
ASPEN PLUS User Gui de The three-vol ume ASPEN PLUS User Guide
provi des step-by-step procedures for devel opi ng and usi ng an ASPEN PLUS
process si mul ati on model . The gui de i s task -ori ented to hel p you accompl i sh the
engi neeri ng work you need to do, usi ng the powerful capabi l i ti es of
ASPEN PLUS.
ASPEN PLUS reference manual seri es ASPEN PLUS reference manual s
provi de detai l ed techni cal reference i nformati on. These manual s i ncl ude
background i nformati on about the uni t operati on model s and the physi cal
properti es methods and model s avai l abl e i n ASPEN PLUS, tabl es of
ASPEN PLUS databank parameters, group contri buti on method functi onal
groups, and a wi de range of other reference i nformati on. The set compri ses:
Unit Operation Models
Physical Property Methods and Models
Physical Property Data
User Models
System Management
Summary File Toolkit
ASPEN PLUS appl i cati on exampl es A sui te of sampl e onl i ne ASPEN PLUS
si mul ati ons i l l ustrati ng speci fi c processes i s del i vered wi th ASPEN PLUS.
ASPEN PLUS I nstal l ati on Gui des These gui des provi de i nstructi ons on
pl atform and network i nstal l ati on of ASPEN PLUS. The set compri ses:
ASPEN PLUS I nstallation Guide for Wi ndows
ASPEN PLUS I nstallation Guide for OpenVMS
ASPEN PLUS I nstallation Guide for UNI X
The ASPEN PLUS manual s are del i vered i n Adobe portabl e document format
(PDF) on the ASPEN PLUS Documentati on CD. You can al so order pri nted
manual s from AspenTech.
Uni t Operati on Model s xi
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O O O O
xi i Uni t Operati on Model s
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Uni t Operati on Model s 1-1
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Chapter 1
1 Mixers and Splitters
Thi s chapter descri bes the uni t operati on model s for mi xi ng and spl i tti ng
streams. The model s are:
Model Description Purpose Use For
Mixer Stream mixer Combines multiple streams
into one stream
Mixing tees. Stream mixing operations.
Adding heat streams. Adding work streams
FSplit Stream splitter Divides feed based on splits
specified for outlet streams
Stream splitters. Bleed valves
SSplit Substream splitter Divides feed based on splits
specified for each
substream
Stream splitters. Perfect fluid-solid
separators
1-2 Uni t Operati on Model s
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Mixers and
Splitters
Mixer
Stream Mixer
Use Mi xer to combi ne streams i nto one stream. Mi xer model s mi xi ng tees or other
types of mi xi ng operati ons.
Mi xer combi nes materi al streams (or heat streams or work streams) i nto one
stream. Sel ect the Heat (Q) and Work (W) Mi xer i cons from the Model Li brary for
heat and work streams respecti vel y. A si ngl e Mi xer bl ock cannot mi x streams of
di fferent types (materi al , heat, work).
Flowsheet Connectivity for Mixer
Material
Water (optional)
Material
(2 or more)
Flowsheet for Mixing Material Streams
Material Streams
Inlet At l east two materi al streams
Outlet One materi al stream
One water decant stream (opti onal )
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Chapter 1
Heat
Heat
(2 or more)
Flowsheet for Adding Heat Streams
Heat Streams
Inlet At l east two heat streams
Outlet One heat stream
Work
Work
(2 or more)
Flowsheet for Adding Work Streams
Work Streams
Inlet At l east two work streams
Outlet One work stream
Specifying Mixer
Use the Mi xer I nput Fl ash Opti ons sheet to speci fy operati ng condi ti ons.
When mi xi ng heat or work streams, Mi xer does not requi re any speci fi cati ons.
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Mixers and
Splitters
When mi xi ng materi al streams, you can speci fy ei ther the outl et pressure or
pressure drop. I f you speci fy pressure drop, Mi xer determi nes the mi ni mum of
the i nl et stream pressures, and appl i es the pressure drop to the mi ni mum i nl et
stream pressure to compute the outl et pressure. I f you do not speci fy the outl et
pressure or pressure drop, Mi xer uses the mi ni mum pressure from the i nl et
streams for the outl et pressure.
You can sel ect the fol l owi ng val i d phases:
Valid Phase Solids? Number of phases? Free Water? Phase?
Vapor-Only Yes or no 1 No V
Liquid-Only Yes or no 1 No L
Vapor-Liquid Yes or no 2 No
Vapor-Liquid-Liquid Yes or no 3 No
Liquid Free-Water
Yes or no 1 Yes
Vapor-Liquid Free-Water
Yes or no 2 Yes
Solid-Only Yes 1 No S
Check Use Free Water Calculations checkbox on the Setup Specifications Global sheet.
An opti onal water decant stream can be used when free-water cal cul ati ons are
performed.
Mi xer performs an adi abati c cal cul ati on on the product to determi ne the outl et
temperature, unl ess Mass Bal ance Onl y Cal cul ati ons i s speci fi ed on the Mi xer
Bl ockOpti ons Si mul ati onOpti ons sheet or the Setup Si mul ati onOpti ons
Cal cul ati ons sheet.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Mi xer:
Use this form To do this
Input Enter operating conditions and flash convergence parameters
BlockOptions Override global values for physical properties, simulation options, diagnostic message levels,
and report options for this block
Results View Mixer simulation results
Dynamic Specify parameters for dynamic simulations
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Chapter 1
FSplit
Stream Splitter
FSpl i t combi nes streams of the same type (materi al , heat, or work streams) and
di vi des the resul ti ng stream i nto two or more streams of the same type. Al l outl et
streams have the same composi ti on and condi ti ons as the mi xed i nl et. Sel ect the
Heat (Q) and Work (W) FSpl i t i cons from the Model Li brary for heat and work
streams respecti vel y. Use FSpl i t to model fl ow spl i tters, such as bl eed val ves.
FSpl i t cannot spl i t a stream i nto di fferent types. For exampl e, FSpl i t cannot spl i t
a materi al stream i nto a heat stream and a materi al stream.
To model a spl i tter where the amount of each substream sent to each outl et can
di ffer, use an SSpl i t bl ock. To model a spl i tter where the composi ti on and
properti es of the output streams can di ffer, use a Sep bl ock or a Sep2 bl ock.
Flowsheet Connectivity for FSplit
Material
(2 or more)
Material
(any number)
Flowsheet for Splitting Material Streams
Material Streams
Inlet At l east one materi al stream
Outlet At l east two materi al streams
Versi on 10
Mixers and
Splitters
Heat
(2 or more) Heat
(any number)
Flowsheet for Splitting Heat Streams
Heat Streams
Inlet At l east one heat stream
Outlet At l east two heat streams
Work
(2 or more) Work
(any number)
Flowsheet for Splitting Work Streams
Work Streams
Inlet At l east one work stream
Outlet At l east two work streams
Specifying FSplit
To spl i t materi al streams Gi ve one of the fol l owi ng speci fi cati ons for each
outl et stream except one:
Fracti on of the combi ned i nl et fl ow
Mol e fl ow rate
Mass fl ow rate
Standard l i qui d vol ume fl ow rate
Actual vol ume fl ow rate
Fracti on of the resi due remai ni ng after al l other speci fi cati ons are sati sfi ed
FSpl i t puts any remai ni ng fl ow i n the unspeci fi ed outl et stream to sati sfy materi al
bal ance. You can speci fy mol e, mass, or standard l i qui d vol ume fl ow rate for one of
the fol l owi ng:
The enti re stream
A subset of key components i n the stream
Versi on 10
Chapter 1
To speci fy the fl ow rate of a component or group of components i n an outl et stream,
speci fy a group of key components and the total fl ow rate for the group (the sum of
the component fl ow rates) on the I nput Speci fi cati ons sheet, and defi ne the key
components i n the group on the I nput KeyComponents sheet.
Outl et streams have the same composi ti on as the mi xed i nl et stream. For thi s
reason, when you speci fy the fl ow rate of a key component, the total fl ow rate of
the outl et stream i s greater than the fl ow rate you speci fy.
When FSpl i t has more than one i nl et, you can do one of the fol l owi ng:
Enter the outl et pressure on the FSpl i t I nput Fl ashOpti ons sheet
Let the outl et pressure defaul t to the mi ni mum pressure of the i nl et streams
To spl i t heat streams or work streams Speci fy the fracti on of the combi ned
i nl et heat or work for each outl et stream except one. FSpl i t puts any remai ni ng
heat or work i n the unspeci fi ed outl et stream to sati sfy energy bal ance.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for FSpl i t:
Input Enter split specifications, flash conditions and calculation options, and key
components associated with split specifications
BlockOptions Override global values for physical properties, simulation options,
diagnostic message levels, and report options for this block
Results View split fractions for outlet streams, and material and energy balance
results
Versi on 10
Mixers and
Splitters
SSplit
Substream Splitter
SSpl i t combi nes materi al streams and di vi des the resul ti ng stream i nto two or
more streams. Use SSpl i t to model a spl i tter where the spl i t of each substream
among the outl et streams can di ffer.
Substreams i n the outl et streams have the same composi ti on, temperature, and
pressure as the correspondi ng substreams i n the mi xed i nl et stream. Onl y the
substream fl ow rates di ffer. To model a spl i tter i n whi ch the composi ti on and
properti es of the substreams i n the output streams can di ffer, use a Sep bl ock or
a Sep2 bl ock.
Flowsheet Connectivity for SSplit
Material
(2 or more)
Material
(any number)
Material Streams
Specifying SSplit
For each substream, speci fy one of the fol l owi ng for al l but one outl et stream:
Fracti on of the i nl et substream
Mol e fl ow rate
Mass fl ow rate
Standard l i qui d vol ume fl ow rate
SSpl i t puts any remai ni ng fl ow for each substream i n the unspeci fi ed stream.
You cannot speci fy standard l i qui d vol ume fl ow rate when the substream i s of
type CI SOLI D, and mol e and standard l i qui d vol ume fl ow rates when the
substream i s of type NC.
Versi on 10
Chapter 1
You can speci fy mol e or mass fl ow rate for one of the fol l owi ng:
The enti re substream
A subset of components i n the substream
You can speci fy the fl ow rate of a component i n a substream of an outl et stream. To
do thi s, defi ne a key component and speci fy the fl ow rate for the key component.
Si mi l arl y, you can speci fy the fl ow rate for a group of components i n a substream of
an outl et stream. To do thi s, defi ne a key group of components and speci fy the total
fl ow rate for the group (the sum of the component fl ow rates).
Substreams i n outl et streams have the same composi ti on as the correspondi ng
substream i n the mi xed i nl et stream. For thi s reason, when you speci fy the fl ow
rate of a key, the total fl ow rate of the substream i n the outl et stream i s greater
than the fl ow rate you speci fy.
When SSpl i t has more than one i nl et, you can do one of the fol l owi ng:
Enter the outl et pressure on the I nput Fl ashOpti ons sheet.
Let the outl et pressure defaul t to the mi ni mum pressure of the i nl et streams.
The composi ti on, temperature, pressure, and other substream vari abl es for al l
outl et streams have the same val ues as the mi xed i nl et. Onl y the substream fl ow
rates di ffer.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for SSpl i t:
Input Enter split specifications, flash conditions, calculation options, and key components
associated with split specifications
BlockOptions Override global values for physical properties, simulation options, diagnostic message
levels, and report options for this block
Results View split fractions of each substream in each outlet stream, and material and energy
balance results
O O O O
Versi on 10
Mixers and
Splitters
Versi on 10
Chapter 2
2 Separators
Thi s chapter descri bes the uni t operati on model s for component separators, fl ash
drums, and l i qui d-l i qui d separators. The model s are:
Flash2 Two-outlet flash Separates feed into two outlet
streams, using rigorous vapor-
liquid or vapor-liquid-liquid
equilibrium
Flash drums, evaporators, knock-out
drums, single stage separators
Flash3 Three-outlet flash Separates feed into three
outlet streams, using rigorous
vapor-liquid-liquid equilibrium
Decanters, single-stage separators with
two liquid phases
Decanter Liquid-liquid decanter Separates feed into two liquid
outlet streams
Decanters, single-stage separators with
two liquid phases and no vapor phase
Sep Component separator Separates inlet stream
components into multiple outlet
streams, based on specified
flows or split frractions
Component separation operations, such
as distillation and absorption, when the
details of the separation are unknown or
unimportant
Sep2 Two-outlet component
separator
Separates inlet stream
components into two outlet
streams, based on specified
flows, split fractions, or purities
Component separation operations, such
as distillation and absorption, when the
details of the separation are unknown or
unimportant
You can generate heati ng or cool i ng curve tabl es for Fl ash2, Fl ash3, and
Decanter model s.
Versi on 10
Separators
Flash2
Two-Outlet Flash
Use Fl ash2 to model fl ashes, evaporators, knock-out drums, and other si ngl e-
stage separators. Fl ash2 performs vapor-l i qui d or vapor-l i qui d-l i qui d equi l i bri um
cal cul ati ons. When you speci fy the outl et condi ti ons, Fl ash2 determi nes the
thermal and phase condi ti ons of a mi xture of one or more i nl et streams.
Flowsheet Connectivity for Flash2
Vapor
Liquid
Water (optional)
Heat (optional)
Heat
(optional)
Material
(any number)
Material Streams
Outlet One materi al stream for the vapor phase
One materi al stream for the l i qui d phase. (I f three phases exi st, the l i qui d
outl et contai ns both l i qui d phases.)
You can speci fy l i qui d and/or sol i d entrai nment i n the vapor stream.
Versi on 10
Chapter 2
Heat Streams
Inlet Any number of heat streams (opti onal )
Outlet One heat stream (opti onal )
I f you gi ve onl y one speci fi cati on (temperature or pressure) on the I nput
Speci fi cati ons Sheet, Fl ash2 uses the sum of the i nl et heat streams as a duty
speci fi cati on. Otherwi se, Fl ash2 uses the i nl et heat stream onl y to cal cul ate the
net heat duty. The net heat duty i s the sum of the i nl et heat streams mi nus the
actual (cal cul ated) heat duty.
You can use an opti onal outl et heat stream for the net heat duty.
Specifying Flash2
Use the I nput Speci fi cati ons sheet for al l requi red speci fi cati ons and val i d
phases. For val i d phases you can choose the fol l owi ng opti ons:
You can choose the following
options Solids? Number of phases? Free Water?
Vapor-Liquid Yes or no 2 No
Vapor-Liquid-Liquid Yes or no 3 No
Vapor-Liquid-FreeWater Yes or no 2 Yes
Use the I nput Fl ashOpti ons sheet to speci fy temperature and pressure esti mates
and fl ash convergence parameters.
Use the I nput Entrai nment sheet to speci fy l i qui d and sol i d entrai nment i n the
vapor phase.
Use the Hcurves form to speci fy opti onal heati ng or cool i ng curves.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Fl ash2:
Input Enter flash specifications, flash convergence parameters, and entrainment specifications
Hcurves Specify heating or cooling curve tables and view tabular results
Block Options Override global values for physical properties, simulation options, diagnostic message
Results View Flash2 simulation results
Versi on 10
Separators
Solids
Al l phases are i n thermal equi l i bri um. Sol i ds l eave at the same temperature as
the fl ui d phases.
Fl ash2 can si mul ate fl ui d phases wi th sol i ds when the stream contai ns sol i d
substreams or when you request el ectrol ytes chemi stry cal cul ati ons.
Sol i d Substreams Materi al s i n sol i d substreams do not parti ci pate i n phase
equi l i bri um cal cul ati ons.
El ectrol yte Chemi stry Cal cul ati ons You can request these on the Properti es
Speci fi cati ons Gl obal sheet or the Bl ockOpti ons Properti es sheet. Sol i d sal ts
parti ci pate i n l i qui d-sol i d phase equi l i bri um and thermal equi l i bri um
cal cul ati ons. The sal ts are i n the MI XED substream.
Versi on 10
Chapter 2
Flash3
Three-Outlet Flash
Use Fl ash3 to model fl ashes, evaporators, knock-out drums, decanters, and other
si ngl e-stage separators i n whi ch two l i qui d outl et streams are produced. Fl ash3
performs vapor-l i qui d-l i qui d equi l i bri um cal cul ati ons. When you speci fy outl et
condi ti ons, Fl ash3 determi nes the thermal and phase condi ti ons of a mi xture of
one or more i nl et streams.
Flowsheet Connectivity for Flash3
Vapor
2nd Liquid
1st Liquid
Heat (optional)
Heat
(optional)
Material
(any number)
Material Streams
One materi al stream for the fi rst l i qui d phase
One materi al stream for the second l i qui d phase
You can speci fy l i qui d entrai nment of each l i qui d phase i n the vapor stream. You
can al so speci fy entrai nment for each sol i d substream i n the vapor and fi rst
l i qui d phase.
Versi on 10
Separators
Heat Streams
I f you gi ve onl y one speci fi cati on on the I nput Speci fi cati ons Sheet (temperature
or pressure), Fl ash3 uses the sum of the i nl et heat streams as a duty
speci fi cati on. Otherwi se, Fl ash3 uses the i nl et heat stream onl y to cal cul ate the
net heat duty. The net heat duty i s the sum of the i nl et heat streams mi nus the
actual (cal cul ated) heat duty.
Specifying Flash3
Use the I nput Speci fi cati ons sheet for al l requi red speci fi cati ons.
Use the I nput Entrai nment sheet to speci fy sol i d entrai nment.
To speci fy opti onal heati ng or cool i ng curves, use the Hcurves form.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Fl ash3:
Input Enter flash specifications, key components, flash convergence parameters, and
entrainment specifications
Block Options Override global values for physical properties, simulation options, diagnostic
message levels, and report options for this block
Results View Flash3 simulation results
Solids
the fl ui d phases.
Fl ash3 can si mul ate fl ui d phases wi th sol i ds when the stream contai ns sol i d
substreams, or when you request el ectrol yte chemi stry cal cul ati ons.
Versi on 10
Chapter 2
Speci fi cati ons Gl obal sheet or on the I nput Bl ockOpti ons Properti es sheet. Sol i d
sal ts do parti ci pate i n l i qui d-sol i d phase equi l i bri um and thermal equi l i bri um
cal cul ati ons. You can onl y speci fy apparent component cal cul ati ons (Sel ect
Si mul ati on Approach=Apparent Components on the Bl ockOpti ons Properti es
sheet). The sal ts wi l l not appear i n the MI XED substream.
Versi on 10
Separators
Decanter
Liquid-Liquid Decanter
Decanter si mul ates decanters and other si ngl e stage separators wi thout a vapor
phase. Decanter can perform:
Li qui d-l i qui d equi l i bri um cal cul ati ons
Li qui d-free-water cal cul ati ons
Use Decanter to model knock-out drums, decanters, and other si ngl e-stage
separators wi thout a vapor phase. When you speci fy outl et condi ti ons, Decanter
determi nes the thermal and phase condi ti ons of a mi xture of one or more i nl et
streams.
Decanter can cal cul ate l i qui d-l i qui d di stri buti on coeffi ci ents usi ng:
An acti vi ty coeffi ci ent model
An equati on of state capabl e of representi ng two l i qui d phases
A user-speci fi ed Fortran subrouti ne
A bui l t-i n correl ati on wi th user-speci fi ed coeffi ci ents
You can enter component separati on effi ci enci es, assumi ng equi l i bri um stage i s
present.
Use Fl ash3 i f you suspect any vapor phase formati on.
Flowsheet Connectivity for Decanter
Heat
(optional)
Heat
(optional)
1st Liquid
2nd Liquid
Material
(any number)
Material Streams
Outlet One materi al stream for the fi rst l i qui d phase
One materi al stream for the second l i qui d phase
You can speci fy entrai nment for each sol i d substream i n the fi rst l i qui d phase.
Versi on 10
Chapter 2
Heat Streams
I f you speci fy onl y pressure on the I nput Speci fi cati ons sheet, Decanter uses the
sum of the i nl et heat streams as a duty speci fi cati on. Otherwi se, Decanter uses
the i nl et heat stream onl y to cal cul ate the net heat duty. The net heat duty i s the
sum of the i nl et heat streams mi nus the actual (cal cul ated) heat duty.
Specifying Decanter
You can operate Decanter i n one of the fol l owi ng ways:
Adi abati cal l y
Wi th speci fi ed duty
At a speci fi ed temperature
Use the I nput Speci fi cati ons sheet to enter:
Pressure
Temperature or duty
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Decanter:
Input Specify operating conditions, key components, calculation options, valid phases,
efficiency, and entrainment
Properties Specify and/or override property methods, KLL equation parameters, and/or user
subroutine for phase split calculations
Results Display simulation results
Versi on 10
Separators
Defining the Second Liquid Phase
I f two l i qui d phases are present at the decanter operati ng condi ti on, Decanter
treats the phase wi th hi gher densi ty as the second phase, by defaul t.
When onl y one l i qui d phase exi sts and you want to avoi d ambi gui ti es, you can
overri de the defaul t by:
Speci fyi ng key components for i denti fyi ng the second l i qui d phase on the
I nput Speci fi cati ons sheet
Opti onal l y speci fyi ng the threshol d key component mol e fracti on on the I nput
Speci fi cati ons sheet
When Decanter treats the
Two liquid phases are present Phase with the higher mole fraction of key components as the second liquid phase
One liquid phase is present Liquid phase as the first liquid phase, unless the mole fraction of key components exceeds
the threshold value
Methods for Calculating the Liquid-Liquid Distribution
Coefficients (KLL)
When cal cul ati ng l i qui d-l i qui d di stri buti on coeffi ci ents (KLL), by defaul t
Decanter uses the physi cal property method speci fi ed for the bl ock on the
Properti es PhaseProperty sheet or Bl ockOpti ons Properti es sheet.
On the I nput Cal cul ati onOpti ons sheet, you can overri de the defaul t by doi ng one
of the fol l owi ng:
Speci fy separate property methods for the two l i qui d phases usi ng the
Properti es PhaseProperty sheet
Use a bui l t-i n KLL correl ati on. Enter correl ati on coeffi ci ents on the
Properti es KLLCorrel ati on sheet.
Use a Fortran subrouti ne that you speci fy on the Properti es KLLSubrouti ne
sheet
See ASPEN PLUS User Models for more i nformati on about wri ti ng Fortran
subrouti nes.
Phase Splitting
Decanter has two methods for sol vi ng l i qui d-l i qui d phase spl i t cal cul ati ons:
Equati ng fugaci ti es of two l i qui d phases
Mi ni mi zi ng Gi bbs free energy of the system
You can sel ect a method on the I nput Cal cul ati onOpti ons sheet.
Versi on 10
Chapter 2
I f you sel ect Mi ni mi zi ng Gi bbs free energy of the system, the fol l owi ng must be
thermodynami cal l y consi stent:
Physi cal property model s
Bl ock property method
You cannot use the Mi ni mi zi ng Gi bbs free energy of the system method when:
You specify On this sheet
Separate property methods for the two liquid
phases
Properties PhaseProperty
The built-in correlation for liquid-liquid
distribution coefficient ( KLL) calculations
Input CalculationOptions
A user subroutine for liquid-liquid distribution
coefficient (KLL) calculations
Input Calculation Options
Equati ng fugaci ti es of two l i qui d phases i s not restri cted by physi cal property
speci fi cati ons. However, Decanter can cal cul ate sol uti ons that do not mi ni mi ze
Gi bbs free energy.
Efficiency
Decanter outl et streams are normal l y at equi l i bri um. However, you can speci fy
separati on effi ci enci es on the I nput Effi ci ency sheet to account for departure from
equi l i bri um. I f you sel ect Li qui d-FreeWater for Val i d Phases on the I nput
Cal cul ati onOpti ons sheet, you cannot speci fy separati on effi ci enci es.
Solids Entrainment
I f sol i ds substreams are present, they do not parti ci pate i n phase equi l i bri um
cal cul ati ons, but they do parti ci pate i n enthal py bal ance. You can use the I nput
Entrai nment sheet to speci fy sol i ds entrai nment i n the fi rst l i qui d outl et stream.
Decanter pl aces any remai ni ng sol i ds i n the second l i qui d outl et stream.
Versi on 10
Separators
Sep
Component Separator
Sep combi nes streams and separates the resul t i nto two or more streams
accordi ng to spl i ts speci fi ed for each component. When the detai l s of the
separati on are unknown or uni mportant, but the spl i ts for each component are
known, you can use Sep i n pl ace of a ri gorous separati on model to save
computati on ti me .
I f the composi ti on and condi ti ons of al l outl et streams of the bl ock you are
model i ng are i denti cal , you can use an FSpl i t bl ock i nstead of Sep.
Flowsheet Connectivity for Sep
Heat
(optional)
Material
(2 or more)
Material
(any number)
Material Streams
Heat Streams
Inlet No i nl et heat streams
Outlet One stream for the enthal py di fference between i nl et and outl et materi al
streams (opti onal )
Versi on 10
Chapter 2
Specifying Sep
For each substream of each outl et stream except one, use the Sep I nput
Speci fi cati ons sheet to speci fy one of the fol l owi ng for each component present:
Fracti on of the component i n the correspondi ng i nl et substream
Mol e fl ow rate of the component
Mass fl ow rate of the component
Standard l i qui d vol ume fl ow rate of the component
Sep puts any remai ni ng fl ow i n the correspondi ng substream of the unspeci fi ed
outl et stream.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Sep:
Input Enter split specifications, flash specifications, and convergence parameters for the mixed inlet
and each outlet stream
Results View Sep simulation results
Inlet Pressure
Use the Sep I nput Feed Fl ash sheet to speci fy ei ther the pressure drop or the
pressure at the i nl et. Thi s i s useful when Sep has more than one i nl et stream. The
i nl et pressure defaul ts to the mi ni mum i nl et stream pressure.
Outlet Stream Conditions
Use the Sep I nput Outl et Fl ash sheet to speci fy the condi ti ons of the outl et
streams. I f you do not speci fy the condi ti ons for a stream, Sep uses the i nl et
temperature and pressure.
Versi on 10
Separators
Sep2
Two-Outlet Component Separator
Sep2 separates i nl et stream components i nto two outl et streams. Sep2 i s si mi l ar to
Sep, but offers a wi der vari ety of speci fi cati ons. Sep2 al l ows puri ty (mol e-fracti on)
speci fi cati ons for components.
You can use Sep2 i n pl ace of a ri gorous separati on model , such as di sti l l ati on or
absorpti on. Sep2 saves computati on ti me when detai l s of the separati on are
unknown or uni mportant.
I f the composi ti on and condi ti ons of al l outl et streams of the bl ock you are
model i ng are i denti cal , you can use FSpl i t i nstead of Sep2.
Flowsheet Connectivity for Sep2
Material
Material
Heat
(optional)
Material
(any number)
Material Streams
Outlet Two materi al streams
Heat Streams
Outlet One stream for the enthal py di fference between i nl et and outl et materi al
streams (opti onal )
Versi on 10
Chapter 2
Specifying Sep2
Use the I nput Speci fi cati ons sheet to speci fy stream and/or component fracti ons
and fl ows. The number of speci fi cati ons for each substream must equal the
number of components i n that substream.
You can enter these stream speci fi cati ons:
Fracti on of the total i nl et stream goi ng to ei ther outl et stream
Total mass fl ow rate of an outl et stream
Total mol ar fl ow rate of an outl et stream (for substreams of type MI XED or
CI SOLI D)
Total standard l i qui d vol ume fl ow rate of an outl et stream (for substreams of
type MI XED)
You can enter these component speci fi cati ons:
Fracti on of a component i n the feed goi ng to ei ther outl et stream
Mass fl ow rate of a component i n an outl et stream
Mol ar fl ow rate of a component i n an outl et stream (for substreams of type
MI XED or CI SOLI D)
Standard l i qui d vol ume fl ow rate of a component i n an outl et stream (for
substreams of type MI XED)
Mass fracti on of a component i n an outl et stream
Mol e fracti on of a component i n an outl et stream (for substreams of type
MI XED or CI SOLI D)
Sep2 treats each substream separatel y. Do not:
Speci fy the total fl ow of both outl et streams
Enter more than one fl ow or frac speci fi cati on for each component
Enter both a mol e-frac and a mass-frac speci fi cati on for a component i n a
stream
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Sep2:
Input Enter split specifications, flash specifications, and convergence parameters for the mixed inlet
and each outlet stream
Block Options Override global values for physical properties, simulation options, diagnostic message levels,
Results View Sep2 simulation results
Versi on 10
Separators
Inlet Pressure
Use the I nput Feed Fl ash sheet to speci fy ei ther the pressure drop or pressure at
the i nl et. Thi s i nformati on i s useful when Sep2 has more than one i nl et stream.
The i nl et pressure defaul ts to the mi ni mum of the i nl et stream pressures.
Outlet Stream Conditions
Use the I nput Outl et Fl ash sheet to speci fy the condi ti ons of the outl et streams.
I f you do not speci fy the condi ti ons for a stream, Sep2 uses the i nl et temperature
and pressure.
O O O O
Versi on 10
Chapter 3
3 Heat Exchangers
Thi s chapter descri bes the uni t operati on model s for heat exchangers and heaters
(and cool ers), and for i nterfaci ng to the B-JAC heat exchanger programs. The
model s are:
Heater Heater or cooler Determines thermal and phase
conditions of outlet stream
Heaters, coolers, condensers, and so on
HeatX Two-stream heat exchanger Exchanges heat between two
streams
Two-stream heat exchangers. Rating
shell and tube heat exchangers when
geometry is known.
MHeatX Multistream heat exchanger Exchanges heat between any
number of streams
Multiple hot and cold stream heat
exchangers. Two-stream heat
exchangers. LNG exchangers.
Hetran Shell and tube heat
exchanger
Provides interface to the
B-JAC Hetran shell and tube
heat exchanger program
Shell and tube heat exchangers,
including kettle reboilers
Aerotran Air-cooled heat exchanger Provides interface to the
B-JAC Aerotran air-cooled heat
exchanger program
Crossflow heat exchangers, including air
coolers
Versi on 10
Heat
Exchangers
Heater
Heater/Cooler
You can use Heater to represent:
Heaters
Cool ers
Val ves
Pumps (whenever work-rel ated resul ts are not needed)
Compressors (whenever work-rel ated resul ts are not needed)
You al so can use Heater to set the thermodynami c condi ti on of a stream.
When you speci fy the outl et condi ti ons, Heater determi nes the thermal and
phase condi ti ons of a mi xture wi th one or more i nl et streams.
Flowsheet Connectivity for Heater
Heat (optional)
Material
Material
(any number)
Heat
(optional)
Water (optional)
Material Streams
Heat Streams
Versi on 10
Chapter 3
I f you gi ve onl y one speci fi cati on (temperature or pressure) on the Speci fi cati ons
sheet, Heater uses the sum of the i nl et heat streams as a duty speci fi cati on.
Otherwi se, Heater uses the i nl et heat stream onl y to cal cul ate the net heat duty.
The net heat duty i s the sum of the i nl et heat streams mi nus the actual
(cal cul ated) heat duty.
Specifying Heater
Use the Heater I nput Speci fi cati ons sheet for al l requi red speci fi cati ons and val i d
phases.
Dew poi nt cal cul ati ons are two- or three-phase fl ashes wi th a vapor fracti on of
uni ty.
Bubbl e poi nt cal cul ati ons are two- or three-phase fl ashes wi th a vapor fracti on of
zero.
Use the Heater I nput Fl ashOpti ons sheet to speci fy temperature and pressure
esti mates and fl ash convergence parameters.
Use the Hcurves form to speci fy opti onal heati ng or cool i ng curves.
Thi s model has no dynami c features. The pressure drop i s fi xed at the steady
state val ue. The outl et fl ow i s determi ned by the mass bal ance.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Heater.
Input Enter operating conditions and flash convergence parameters
Results View Heater results
Versi on 10
Heat
Exchangers
Solids
Heater can si mul ate fl ui d phases wi th sol i ds when the stream contai ns sol i d
substreams or when you request el ectrol yte chemi stry cal cul ati ons.
fl ui d phases.
Speci fi cati ons Gl obal sheet or the Heater Bl ockOpti ons Properti es sheet. Sol i d
sal ts parti ci pate i n l i qui d-sol i d phase equi l i bri um and thermal equi l i bri um
Versi on 10
Chapter 3
HeatX
Two-Stream Heat Exchanger
HeatX can model a wi de vari ety of shel l and tube heat exchanger types i ncl udi ng:
Countercurrent and cocurrent
Segmental baffl e TEMA E, F, G, H, J, and X shel l s
Rod baffl e TEMA E and F shel l s
Bare and l ow-fi nned tubes
HeatX can perform a ful l zone anal ysi s wi th heat transfer coeffi ci ent and
pressure drop esti mati on for si ngl e- and two-phase streams. For ri gorous heat
transfer and pressure drop cal cul ati ons, you must suppl y the exchanger
geometry.
I f exchanger geometry i s unknown or uni mportant, HeatX can perform si mpl i fi ed
shortcut rati ng cal cul ati ons. For exampl e, you may want to perform onl y heat
and materi al bal ance cal cul ati ons.
HeatX has correl ati ons to esti mate sensi bl e heat, nucl eate boi l i ng, and
condensati on fi l m coeffi ci ents.
HeatX cannot:
Perform desi gn cal cul ati ons
Perform mechani cal vi brati on anal ysi s
Esti mate foul i ng factors
Flowsheet Connectivity for HeatX
Cold Outlet
Water (optional)
Hot Outlet
Water
(optional)
Hot
Inlet
Cold Inlet
Versi on 10
Heat
Exchangers
Material Streams
Inlet One hot i nl et
One col d i nl et
Outlet One hot outl et
One col d outl et
One water decant stream on the hot si de (opti onal )
One water decant stream on the col d si de (opti onal )
Specifying HeatX
Consi der these questi ons when speci fyi ng HeatX:
Shoul d rati ng cal cul ati ons be si mpl e (shortcut) or ri gorous?
What speci fi cati on shoul d the bl ock have?
How shoul d the l og-mean temperature di fference correcti on factor be
cal cul ated?
How shoul d the heat transfer coeffi ci ent be cal cul ated?
How shoul d the pressure drops be cal cul ated?
What equi pment speci fi cati ons and geometry i nformati on are avai l abl e?
The answers to these questi ons determi ne the amount of i nformati on requi red to
compl ete the bl ock i nput. You must provi de one of the fol l owi ng speci fi cati ons:
Heat exchanger area or geometry
Exchanger heat duty
Outl et temperature of the hot or col d stream
Temperature approach at ei ther end of the exchanger
Degrees of superheati ng/subcool i ng for the hot or col d stream
Vapor fracti on of the hot or col d stream
Temperature change of the hot or col d stream
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for HeatX:
Setup Specify shortcut or detailed calculations, flow direction, exchanger pressure drops, heat transfer
coefficient calculation methods, and film coefficients
Options Specify different flash convergence parameters and valid phases for the hot and cold sides, HeatX
convergence parameters, and block-specific report option
Geometry Specify the shell and tube configuration and indicate any tube fins, baffles, or nozzles
UserSubroutines Specify parameters for user-defined Fortran subroutines to calculate overall heat transfer coefficient,
LMTD correction factor, tube-side liquid holdup, or tube-side pressure drop
Hot-Hcurves Specify hot stream heating or cooling curve tables and view tabular results
continued
Versi on 10
Chapter 3
Cold-Hcurves Specify cold stream heating or cooling curve tables and view tabular results
Results View a summary of results, mass and energy balances, pressure drops, velocities, and
zone analysis
Detailed Results View detailed shell and tube results, and information about tube fins, baffles, and
nozzles
Shortcut Versus Rigorous Rating Calculations
HeatX has two rati ng modes: shortcut and ri gorous. Use the Cal cul ati on Type
fi el d on the Setup Speci fi cati ons sheet to speci fy shortcut or ri gorous rati ng
cal cul ati ons.
I n shortcut rati ng mode you can si mul ate a heat exchanger bl ock wi th the
mi ni mum amount of requi red i nput. The shortcut cal cul ati on does not requi re
exchanger confi gurati on or geometry data.
For ri gorous rati ng mode, you can use exchanger geometry to esti mate:
Fi l m coeffi ci ents
Pressure drops
Log-mean temperature di fference correcti on factor
Ri gorous rati ng mode provi des more speci fi cati on opti ons for HeatX, but i t al so
requi res more i nput.
Ri gorous rati ng mode provi des defaul ts for many opti ons. You can change the
defaul ts to gai n compl ete control over the cal cul ati ons. The fol l owi ng tabl e l i sts
these opti ons wi th val i d val ues. The val ues are descri bed i n the fol l owi ng
secti ons.
Versi on 10
Heat
Exchangers
Variable Calculation Method
Available in
Shortcut Mode
Available in
Rigorous Mode
LMTD Correction
Factor
Constant
Geometry
User subroutine
Default
No
No
Yes
Default
Yes
Heat Transfer
Coefficient
Constant value
Phase-specific values
Power law expression
Film coefficients
Exchanger geometry
User subroutine
Yes
Default
Yes
No
No
No
Yes
Yes
Yes
Yes
Default
Yes
Film Coefficient Constant value
Phase-specific values
Power law expression
Calculate from geometry
No
No
No
No
Yes
Yes
Yes
Default
Pressure Drop Outlet pressure
Calculate from geometry
Default
No
Yes
Default
Calculating the Log-Mean Temperature Difference
Correction Factor
The standard equati on for a heat exchanger i s:
Q U A LMTD
where LMTD i s the l og-mean temperature di fference. Thi s equati on appl i es for
exchangers wi th pure countercurrent fl ow.
The more general equati on i s:
Q U A F LMTD
where the LMTD correcti on factor, F, accounts for devi ati on from countercurrent
fl ow.
Use the LMTD Correcti on Factor fi el d on the Setup Speci fi cati ons sheet to enter
the LMTD correcti on factor.
Versi on 10
Chapter 3
I n shortcut rati ng mode, the LMTD correcti on factor i s constant. I n ri gorous
rati ng mode, use the LMTD Correcti on Method fi el d on the Setup Speci fi cati ons
sheet to speci fy how HeatX cal cul ates the LMTD correcti on factor. You can
choose from the fol l owi ng cal cul ati on opti ons:
If LMTD Correction Method is Then
Constant The LMTD correction factor you enter is constant.
Geometry HeatX calculates the LMTD correction factor using the exchanger specification
and stream properties
User subroutine You supply a user subroutine to calculate the LMTD correction factor.
Calculating the Heat Transfer Coefficient
To determi ne how the heat transfer coeffi ci ent i s cal cul ated, set the Cal cul ati on
Method on the Setup U Methods sheet. You can use these opti ons i n shortcut or
ri gorous rati ng mode:
If Calculation Method is HeatX uses And you specify
Constant value A constant value for the heat transfer coefficient The constant value
Phase-specific values A different heat transfer coefficient for each heat transfer
zone of the exchanger, indexed by the phase for the hot
and cold streams
A constant value for
each zone
Power law expression A power law expression for the heat transfer coefficient as
a function of one of the stream flow rates
Constants for the power
law expression
I n ri gorous rati ng mode, three addi ti onal val ues are al l owed:
If Calculation Method is Then
Exchanger geometry HeatX calculates the heat transfer coefficient using exchanger geometry and stream
properties to estimate film coefficients.
Film coefficients HeatX calculates the heat transfer coefficients using the film coefficients. You can use
any option on the Setup Film Coefficients sheet to calculate the film coefficients.
User subroutine You supply a user subroutine to calculate the heat transfer coefficient.
Versi on 10
Heat
Exchangers
Film Coefficients
HeatX does not cal cul ate fi l m coeffi ci ents i n shortcut rati ng mode. I n ri gorous
rati ng mode, i f you use fi l m coeffi ci ents or exchanger geometry for the heat
transfer coeffi ci ent cal cul ati on method, HeatX cal cul ates the heat transfer
coeffi ci ent usi ng:
1 1 1
U h h
c h
+
Where:
h
c
= Col d stream fi l m coeffi ci ent
h
h
= Hot stream fi l m coeffi ci ent
To choose an opti on for cal cul ati ng fi l m coeffi ci ents, set the Cal cul ati on Method
on the Setup Fi l m Coeffi ci ents sheet. The fol l owi ng are avai l abl e:
If Calculation Method is HeatX uses And you specify
Constant value A constant value for the film coefficient A constant value to be
used throughout the
exchanger
Phase-specific values A different film coefficient for each heat
transfer zone (phase) of the exchanger,
indexed by the phase of the stream
A constant value for
each phase
Power law expression A power law expression for the film coefficient
as a function of the stream flow rate
Constants for the power
law expression
Calculate from geometry The exchanger geometry and stream
properties to calculate the film coefficient
The hot stream and col d stream fi l m coeffi ci ent cal cul ati on methods are
i ndependent of each other. You can use any combi nati on that i s appropri ate for
your exchanger.
Pressure Drop Calculations
To enter exchanger pressure or pressure drop for the hot and col d si des, use the
Outl et Pressure fi el ds on the Setup Pressure Drop sheet. I n shortcut rati ng mode
the pressure drop i s constant.
Versi on 10
Chapter 3
I n ri gorous rati ng mode, you can choose how pressure drops are cal cul ated by
setti ng the pressure opti ons on the Setup PressureDrop sheet. The fol l owi ng
pressure drop opti ons are avai l abl e:
If Pressure Option is Then
Outlet Pressure You must enter the outlet pressure or pressure drop for the stream.
Calculate from geometry HeatX calculates the pressure drop using the exchanger geometry and stream
properties
HeatX cal l s the Pi pel i ne model to cal cul ate tube-si de pressure drop. You can set
the correl ati ons for pressure drop and l i qui d hol dup that the Pi pel i ne model uses
on the Setup PressureDrop sheet.
Exchanger Configuration
Exchanger confi gurati on refers to the overal l patterns of fl ow i n the heat
exchanger. I f you choose Cal cul ate From Geometry for any of the heat transfer
coeffi ci ents, fi l m coeffi ci ents, or pressure drop cal cul ati on methods, you may be
requi red to enter some i nformati on about the exchanger confi gurati on on the
Geometry Shel l sheet. Thi s sheet i ncl udes fi el ds for:
TEMA shel l type (see the next fi gure, TEMA Shel l Types)
Number of tube passes
Exchanger ori entati on
Tubes i n baffl e wi ndow
Number of seal i ng stri ps
Tube fl ow for verti cal exchangers
Versi on 10
Heat
Exchangers
Two Pass Shell
with Longitudinal Baffle
One Pass Shell
E Shell
F Shell
G Shell
H Shell
J Shell
X Shell
Split Flow
Double Split Flow
Divided Flow
Cross Flow
TEMA Shell Types
Versi on 10
Chapter 3
The Geometry Shel l sheet al so contai ns two i mportant di mensi ons for the shel l :
I nsi de shel l di ameter
Shel l to bundl e cl earance
The next fi gure shows the shel l di mensi ons.
Outer Tube
Limit
Shell to Bundle
Clearance
Shell Diameter
Shell Dimensions
Baffle Geometry
Cal cul ati on of shel l -si de fi l m coeffi ci ent and pressure drop requi re i nformati on
about the baffl e geometry wi thi n the shel l . Enter baffl e geometry on the
Geometry Baffl es sheet.
HeatX can cal cul ate shel l -si de val ues for both segmental baffl e shel l s and rod
baffl e shel l s. Other requi red i nformati on depends on the baffl e type. For
segmental baffl es, requi red i nformati on i ncl udes:
Baffl e cut
Baffl e spaci ng
Baffl e cl earances
For rod baffl es, requi red i nformati on i ncl udes:
Ri ng di mensi ons
Support rod geometry
Versi on 10
Heat
Exchangers
The next two fi gures show the baffl e di mensi ons. The Baffl e Cut i n the
Di mensi ons for Segmental Baffl es fi gure i s a fracti on of the shel l di ameter. Al l
cl earances are di ametri c.
Baffle Cut
Tube Hole
Shell to Baffle
Clearance
Dimensions for Segmental Baffles
Ring Outside
Diameter
Ring Inside
Diameter
Rod Diameter
Dimensions for Rod Baffles
Tube Geometry
Cal cul ati on of the tube-si de fi l m coeffi ci ent and pressure drop requi re
i nformati on about the geometry of the tubebank. HeatX al so uses thi s
i nformati on to cal cul ate the heat transfer coeffi ci ent from the fi l m coeffi ci ents.
Enter tube geometry on the Geometry Tubes sheet.
Versi on 10
Chapter 3
You can sel ect a heat exchanger wi th ei ther bare or l ow-fi nned tubes. The sheet
al so i ncl udes fi el ds for:
Total number of tubes
Tube l ength
Tube di ameters
Tube l ayout
Tube materi al of constructi on
The next two fi gures show tube l ayout patterns and fi n di mensi ons.
Tube
Pitch
30
o
Triangle
45
o
Tube
Pitch
Rotated
Square
60
o
Tube
Pitch
Rotated
Triangle
90
o
Tube
Pitch
Square
Direction of Flow
Tube Layout Patterns
Outside
Diameter
Fin Thickness
Root Mean
Diameter
Fin Height
Fin Dimensions
Nozzle Geometry
Cal cul ati ons for pressure drop i ncl ude the cal cul ati on of pressure drop i n the
exchanger nozzl es. Enter nozzl e geometry on the Geometry Nozzl es sheet.
Model Correlations
HeatX uses open l i terature correl ati ons for cal cul ati ng fi l m coeffi ci ents and
pressure drops. The next four tabl es l i st the model correl ati ons.
Versi on 10
Heat
Exchangers
Tube-side Heat Transfer Coefficient Correlations
Mechanism Flow Regime Correlation References
Single-phase Laminar
Turbulent
Schlunder
Gnielinski
[1]
[1]
Boiling - vertical tubes Steiner/Taborek [2]
Boiling - horizontal tubes Shah [3, 4]
Condensation - vertical tubes Laminar
Laminar wavy
Turbulent
Shear-dominated
Nusselt
Kutateladze
Labuntsov
Rohsenow
[5]
[6]
[7]
[8]
Condensation - horizontal tubes Annular
Stratifying
Rohsenow
Jaster/Kosky method
[8]
[9]
Shell-side Heat Transfer Coefficient Correlations
Mechanism Flow Regime Correlation References
Single-phase segmental Bell-Delaware [10, 11]
Single-phase ROD Gentry [12]
Boiling Jensen [13]
Condensation - vertical Laminar
Laminar wavy
Turbulent
Shear-dominated
Nusselt
Kutateladze
Labuntsov
Rohsenow
[5]
[6]
[7]
[8]
Condensation - horizontal Kern [9]
Tube-side Pressure Drop Correlations
Mechanism Correlation
Single-phase Darcys Law
Two-phase See Chapter 6
See Pipeline, Two-Phase Correlations, for the correlations available for two-phase pressure drop in a
pipe.
Shell-side Pressure Drop Correlations
Mechanism Correlation References
Single-phase segmental Bell-Delaware [10, 11]
Single-phase ROD Gentry [12]
Two-phase segmental Bell-Delaware method with Grants correction for two-
phase flow
[10, 11], [14]
Two-phase ROD Gentry [12]
Versi on 10
Chapter 3
Flash Specifications
Use the Opti ons Fl ash Opti ons sheet to enter fl ash speci fi cati ons.
If you want to perform
these calculations Solids? Set Valid Phases to
Vapor phase Yes or no Vapor-only
Liquid phase Yes or no Liquid-only
2-fluid flash phase Yes or no Vapor-Liquid
3-fluid flash phase Yes or no Vapor-Liquid-Liquid
3-fluid phase free-water flash Yes or no Vapor-Liquid-FreeWater
Solids only Yes Solid-only
Physical Properties
To overri de gl obal or fl owsheet secti on property speci fi cati ons, use the
Bl ockOpti ons Properti es sheet. You can use di fferent physi cal property opti ons
for the hot si de and col d si de of the heat exchanger. I f you suppl y onl y one set of
property speci fi cati ons, HeatX uses that set for both hot and col d si de
cal cul ati ons.
Solids
the fl ui d phases.
HeatX can si mul ate fl ui d phases wi th sol i ds when the stream contai ns sol i d
Speci fi cati ons Gl obal sheet or HeatX Bl ockOpti ons Properti es sheet. Sol i d sal ts
parti ci pate i n l i qui d-sol i d phase equi l i bri um and thermal equi l i bri um
Versi on 10
Heat
Exchangers
References
1. Gni el i nski , V., "Forced Convecti on i n Ducts." I n: Heat Exchanger Desi gn
Handbook. New York: Hemi sphere Publ i shi ng Corporati on, 1983.
2. Stei ner, D. and Taborek, J., "Fl ow Boi l i ng Heat Transfer i n Verti cal Tubes
Correl ated by an Asymptoti c Model ." I n: Heat Transfer Engi neeri ng, 13(2):43-
69, 1992.
3. Shah, M.M., "A New Correl ati on for Heat Transfer Duri ng Boi l i ng Fl ow
Through Pi pes." I n: ASHRAE Transacti ons, 82(2):66-86, 1976.
4. Shah, M.M., "Chart Correl ati on for Saturated Boi l i ng Heat Transfer:
Equati ons and Further Study." I n: ASHRAE Transacti ons, 87(1):185-196,
1981.
5. Nussel t, W., "Surface Condensati on of Water Vapor." Z. Ver. Dtsch, I ng.,
60(27):541-546, 1916.
6. Kutatel adze, S.S., Fundamental s of Heat Transfer. New York: Academi c
Press, 1963.
7. Labuntsov, D.A., "Heat Transfer i n Fi l m Condensati on of Pure Steam on
Verti cal Surfaces and Hori zontal Tubes." I n: Tepl oenergeti ka, 4(7):72-80,
1957.
8. Rohsenow, W.M., Webber, J.H., and Li ng, A.T., "Effect of Vapor Vel oci ty on
Lami nar and Turbul ent Fi l m Condensati on." I n: Transacti ons of the ASME,
78:1637-1643, 1956.
9. Jaster, H. and Kosky, P.G., "Condensati on Heat Transfer i n a Mi xed Fl ow
Regi me." I n: I nternati onal Journal of Heat and Mass Transfer, 19:95-99,
1976.
10. Taborek, J., "Shel l -and-Tube Heat Exchangers: Si ngl e Phase Fl ow." I n: Heat
Exchanger Desi gn Handbook. New York: Hemi sphere Publ i shi ng
Corporati on, 1983.
11. Bel l , K.J., "Del aware Method for Shel l Si de Desi gn." I n: Kakac, S., Bergl es,
A.E., and Mayi nger, F., edi tors, Heat Exchangers: Thermal -Hydraul i c
Fundamental s and Desi gn. New York: Hemi sphere Publ i shi ng Corp., 1981.
12. Gentry, C.C., "RODBaffl e Heat Exchanger Technol ogy." I n: Chemi cal
Engi neeri ng Progress 86(7):48-57, Jul y 1990.
13. Jensen, M.K. and Hsu, J.T., "A Parametri c Study of Boi l i ng Heat Transfer i n
a Tube Bundl e." I n: 1987 ASME-JSME Thermal Engi neeri ng Joi nt
Conference, pages 133-140, Honol ul u, Hawai i , 1987.
14. Grant, I .D.R. and Chi shol m, D., "Two-Phase Fl ow on the Shel l Si de of a
Segmental l y Baffl ed Shel l -and-Tube Heat Exchanger." I n: Journal of Heat
Transfer, 101(1):38-42, 1979.
Versi on 10
Chapter 3
MHeatX
Multistream Heat Exchanger
Use MHeatX to represent heat transfer between mul ti pl e hot and col d streams,
such as i n an LNG exchanger. You can al so use MHeatX for two-stream heat
exchangers. Free water can be decanted from any outl et stream. MHeatX ensures
an overal l energy bal ance but does not account for the exchanger geometry.
MHeatX can perform a detai l ed, ri gorous i nternal zone anal ysi s to determi ne the
i nternal pi nch poi nts and heati ng and cool i ng curves for al l streams i n the heat
exchanger. MHeatX can al so cal cul ate the overal l UA for the exchanger and
model heat l eak to or from an exchanger.
MHeatX uses mul ti pl e Heater bl ocks and heat streams to enhance fl owsheet
convergence. ASPEN PLUS automati cal l y sequences bl ock and stream
convergence unl ess you speci fy a sequence or tear stream.
Flowsheet Connectivity for MHeatX
Hot Inlets
(any number)
Hot Outlets
Water (optional)
Hot Outlets
Water (optional)
Water
(optional)
Cold
Outlets
Cold Inlets
(any number)
Material Streams
Inlet At l east one materi al stream on the hot si de. At l east one materi al stream
on the col d si de
Outlet One outl et stream for each i nl et stream
One water decant stream for each outl et stream (opti onal )
The i nl et stream si des are non-contacti ng.
Versi on 10
Heat
Exchangers
Specifying MHeatX
You must gi ve outl et speci fi cati ons for each stream on one si de of the heat
exchanger. On the other si de you can speci fy any of the outl et streams, but you
must l eave at l east one unspeci fi ed stream.
Di fferent streams can have di fferent types of speci fi cati ons. MHeatX assumes
that al l unspeci fi ed streams have the same outl et temperature. An overal l energy
bal ance determi nes the temperature of any unspeci fi ed stream(s).
You can use a di fferent property method for each stream i n MHeatX. Speci fy the
property methods on the Bl ockOpti ons Properti es sheet.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for MHeatX:
Input Specify operating conditions, flash convergence parameters, parameters for
zone analysis, flash table, MHeatX convergence parameters, and block-specific
report options
BlockOptions Override global values for physical properties, simulation options, diagnostic
message levels and report options for this block
Results View stream results, exchanger results, zone profiles, stream profiles, flash
profiles, and material and energy balance results
Zone Analysis
MHeatX can perform a detai l ed, ri gorous i nternal zone anal ysi s to determi ne:
I nternal pi nch poi nts
UA and LMTD of each zone
Total UA of the exchanger
Overal l average LMTD
To obtai n a zone anal ysi s, speci fy Number of zones greater than 0 on the MHeatX
I nput Zone Anal ysi s sheet. Duri ng zone anal ysi s MHeatX can add:
Stream entry poi nts (i f al l feed streams are not at the same temperature)
Stream exi t poi nts (i f al l product streams are not at the same temperature)
Phase change poi nts (i f a phase change occurs i nternal l y)
MHeatX can al so account for the nonl i neari ti es of zone profi l es by addi ng zones
adapti vel y. MHeatX can perform zone anal ysi s for both countercurrent and co-
current heat exchangers.
Versi on 10
Chapter 3
Using Flash Tables in Zone Analysis
Use Fl ash Tabl es to esti mate zone profi l es and pi nch poi nts qui ckl y. These tabl es
are most useful for heat exchangers that have many streams, for whi ch zone
anal ysi s cal cul ati ons can take a l ong ti me.
To use a Fl ash Tabl e for a stream, speci fy the number of fl ash poi nts for the
stream on the MHeatX I nput Fl ash Tabl e sheet. When you speci fy a fl ash tabl e
for a stream, MHeatX generates a temperature-enthal py profi l e of that stream
before zone anal ysi s, and i nterpol ates that profi l e duri ng zone anal ysi s, rather
than fl ashi ng the stream.
You can al so speci fy the fracti on of total pressure drop i n each phase regi on of a
stream on the MHeatX I nput Fl ash Tabl e sheet. ASPEN PLUS uses these
fracti ons to determi ne the pressure profi l e duri ng Fl ash Tabl e generati on.
Computational Structure for MHeatX
The computati onal structure of MHeatX may affect your speci fi cati ons.
Unl i ke other uni t operati on bl ocks, MHeatX i s not si mul ated by a si ngl e
computati on modul e. I nstead, ASPEN PLUS generates heaters and heat streams
to represent the mul ti stream heat exchanger. A Heater bl ock represents streams
wi th outl et speci fi cati ons. A mul ti stream heater bl ock represents streams wi th
no outl et speci fi cati ons. The next fi gure shows the computati onal structure
generated for a sampl e exchanger.
S3 S4 S5 S6 S7 S8
S1 S2
LNGIN LNGOUT
$LNGH03
$LNGQ03
$LNGQ02
HEATER HEATER
$LNGH02
$LNGQ04
HEATER
$LNGH04
$LNGHTR
MHEATER
Example of MHeatX Computational Structure
Thi s computati onal sequence converges much more rapi dl y than si mul ati on of
MHeatX as a si ngl e bl ock. Bl ock resul ts are gi ven for the enti re MHeatX
sequence. I n most cases, you do not need to know about the i ndi vi dual bl ocks
generated i n the sequence. The fol l owi ng paragraphs descri be the excepti ons.
Versi on 10
Heat
Exchangers
Si mul ati on hi story and control panel messages are gi ven for the generated
Heater bl ocks and heat streams.
You can provi de an esti mate for duty of the i nternal l y generated heat stream. I f
the heat stream i s a tear stream i n the fl owsheet, ASPEN PLUS uses thi s
esti mate as an i ni ti al val ue.
You can gi ve convergence speci fi cati ons for the fl owsheet resul ti ng when MHeatX
bl ocks are repl aced by thei r generated networks. The generated Heater bl ock and
heat stream I Ds must be used on the Convergence SequenceSpeci fi cati ons and
Convergence TearSpeci fi cati ons sheets.
Automati c fl owsheet anal ysi s i s based on the fl owsheet resul ti ng when MHeatX
bl ocks are repl aced by generated Heater bl ocks. The generated Heater bl ocks,
i nstead of the MHeatX bl ock, appear i n the cal cul ati on sequence. You can sel ect
generated heat streams as tear streams.
Solids
MHeatX can si mul ate fl ui d phases wi th sol i ds when the stream contai ns sol i d
the fl ui d phases.
Speci fi cati ons Gl obal sheet or the MHeatX Bl ockOpti ons Properti es sheet. Sol i d
sal ts parti ci pate i n l i qui d-sol i d phase equi l i bri um and thermal equi l i bri um
Versi on 10
Chapter 3
Hetran
Interface to the B-J AC Hetran Program for Shell and Tube Heat
Exchangers
Hetran i s the i nterface to the B-JAC Hetran program for desi gni ng and
si mul ati ng shel l and tube heat exchangers. Hetran can be used to si mul ate shel l
and tube heat exchangers wi th a wi de vari ety of confi gurati ons. To use Hetran,
pl ace the bl ock i n the fl owsheet, connect i nl et and outl et streams, and speci fy a
smal l number of bl ock i nputs, i ncl udi ng the name of the B-JAC i nput fi l e for that
exchanger.
You enter i nformati on rel ated to the heat exchanger confi gurati on and geometry
through the Hetran standal one program i nterface. The exchanger speci fi cati on i s
saved as a B-JAC i nput fi l e. You do not have to enter i nformati on about the
exchangers physi cal characteri sti cs through the ASPEN PLUS user i nterface or
through i nput l anguage.
Flowsheet Connectivity for Hetran
Cold Inlet
Hot Inlet
Hot Water (optional)
Hot Outlet
Cold Outlet
Cold Water (optional)
Material Streams
One col d i nl et
One col d outl et
Versi on 10
Heat
Exchangers
Specifying Hetran
Enter the i nput for the shel l and tube heat exchanger through the Hetran
programs graphi cal user i nterface. The i nput for Hetran i n ASPEN PLUS i s
l i mi ted to:
The B-JAC i nput fi l e name that contai ns the heat exchanger speci fi cati on
A set of parameters to control how property curves are generated
A set of Hetran program i nputs that you can change from wi thi n
ASPEN PLUS (for exampl e, foul i ng factors and fi l m coeffi ci ents)
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Hetran:
Input Specify the name of the B-JAC input file, parameters for calculating the property curves,
optional Hetran program inputs, flash convergence parameters, and valid phases
BlockOption
s
Override global values for physical properties, simulation options, diagnostic message
Results View inlet and outlet stream conditions and material and energy balance results
Detailed
Results
View overall results and detailed results for the shell side and tube side
Use the Fl ashOpti ons sheet to enter fl ash speci fi cati ons.
If you want to perform these calculations Solids? Set Valid Phases to
Versi on 10
Chapter 3
Physical Properties
Fl ashOpti ons sheet. You can use di fferent physi cal property methods for the hot
si de and col d si de of the heat exchanger. I f you suppl y onl y one set of property
speci fi cati ons, Hetran uses that set for both hot- and col d-si de cal cul ati ons.
Solids
Hetran cannot currentl y handl e streams wi th sol i ds substreams.
Versi on 10
Heat
Exchangers
Aerotran
Interface to the B-J AC Aerotran Program for Air-cooled Heat Exchangers
Aerotran i s the i nterface to the B-JAC Aerotran program for desi gni ng and
si mul ati ng ai r-cool ed heat exchangers. Aerotran can be used to si mul ate ai r-
cool ed heat exchangers wi th a wi de vari ety of confi gurati ons. I t can al so be used
to model economi zers and the convecti on secti on of fi red heaters. To use
Aerotran, pl ace the bl ock i n the fl owsheet, connect i nl et and outl et streams, and
speci fy a smal l number of bl ock i nputs, i ncl udi ng the name of the B-JAC i nput
fi l e for that exchanger.
You enter i nformati on rel ated to the ai r cool er confi gurati on and geometry
through the Aerotran standal one program i nterface. The ai r cool er speci fi cati on
i s saved as a B-JAC i nput fi l e. You do not have to enter i nformati on about the ai r
cool ers physi cal characteri sti cs through the ASPEN PLUS user i nterface or
through i nput l anguage.
Flowsheet Connectivity for Aerotran
Cold (Air) Inlet
Cold (Air) Outlet
Hot Outlet
Hot Inlet
Hot Water (optional)
Cold Water (optional)
Material Streams
One col d (ai r) i nl et
One col d (ai r) outl et
Versi on 10
Chapter 3
Specifying Aerotran
Enter the i nput for the ai r-cool ed heat exchanger through the Aerotran programs
graphi cal user i nterface. The i nput for Aerotran i n ASPEN PLUS i s l i mi ted to:
The B-JAC i nput fi l e name that contai ns the heat exchanger speci fi cati on
A set of parameters to control how property curves are generated
A set of Aerotran program i nputs that you can change from wi thi n ASPEN
PLUS (for exampl e, foul i ng factors and fi l m coeffi ci ents)
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Aerotran:
Input Specify the name of the B-JAC input file, parameters for calculating the property
curves, optional Aerotran program inputs, flash convergence parameters, and valid
phases
Results View inlet and outlet stream conditions and material and energy balance results
Detailed Results View overall results, detailed results for the outside and tube side, and fan results
Use the Fl ashOpti ons sheet to enter fl ash speci fi cati ons.
If you want to perform these calculations Solids? Set Valid Phases to
Versi on 10
Heat
Exchangers
Physical Properties
Fl ashOpti ons sheet. You can use di fferent physi cal property methods for the hot
si de and col d si de of the ai r cool er. I f you suppl y onl y one set of property
speci fi cati ons, Aerotran uses that set for both hot- and col d-si de cal cul ati ons.
Solids
Aerotran bl ocks cannot currentl y handl e streams wi th sol i ds substreams.
O O O O
Versi on 10
Chapter 4
4 Columns
Thi s chapter descri bes the uni t operati on model s for di sti l l ati on col umns usi ng
shortcut and ri gorous cal cul ati ons, and for l i qui d-l i qui d extracti on. The model s
are:
DSTWU Shortcut distillation design
using the Winn-
Underwood-Gilliland
method
Determines minimum reflux ratio,
minimum number of stages, and either
actual reflux ratio or actual number of
stages
Columns with one feed
and two product streams
Distl Shortcut distillation rating
using the Edmister method
Determines separation based on reflux
ratio, number of stages, and distillate-to-
feed ratio
Columns with one feed
and two product streams
SCFrac Shortcut distillation for
complex petroleum
fractionation units
Determines product composition and flow,
number of stages per section, and heat
duty using fractionation indices
Complex columns, such as
crude units and vacuum
towers
RadFrac Rigorous fractionation Performs rigorous rating and design
calculations for single columns
Ordinary distillation,
absorbers, strippers,
extractive and azeotropic
distillation, three-phase
distillation, reactive
distillation
MultiFrac Rigorous fractionation for
complex columns
Performs rigorous rating and design
calculations for multiple columns of any
complexity
Heat integrated columns,
air separation columns,
absorber/stripper
combinations ethylene
plant primary fractionator
quench tower
combinations, petroleum
refining applications
continued
Versi on 10
Columns
PetroFrac Petroleum refining
fractionation
Performs rigorous rating and design
calculations for complex columns in
petroleum refining applications
Preflash tower,
atmospheric crude unit,
vacuum unit, catalytic
cracker main fractionator,
delayed coker main
fractionator, vacuum lube
fractionator, ethylene plant
primary fractionator and
quench tower
combinations
RateFrac
Rate-based distillation Performs rigorous rating and design for

single and multiple columns. Based on
nonequilibrium calculations. Does not
require efficiencies and HETPs.
Distillation columns,
absorbers, strippers,
reactive systems, heat
integrated units, petroleum
applications, such as
crude and vacuum units,
absorber-stripper
combination
Extract Rigorous liquid-liquid
extraction
Models countercurrent extraction of a
liquid stream using a solvent
Liquid-liquid extractors
RateFrac requires a separate license and can be used only by customers who have purchased it through
a specific license agreement with Aspen Technology, I nc.
Thi s chapter i s organi zed i nto the fol l owi ng secti ons:
Section Models
Shortcut Distillation DSTWU, Distl, SCFrac
Rigorous Distillation RadFrac, MultiFrac, PetroFrac, RateFrac
Liquid-Liquid Extraction Extract
Versi on 10
Chapter 4
DSTWU
Shortcut Distillation Design
DSTWU performs shortcut desi gn cal cul ati ons for si ngl e-feed, two-product
di sti l l ati on col umns wi th a parti al or total condenser.
DSTWU assumes constant mol al overfl ow and constant rel ati ve vol ati l i ti es.
DSTWU uses this method/correlation To estimate
Winn Minimum number of stages
Underwood Minimum reflux ratio
Gilliland Required reflux ratio for a specified number of stages or the required
number of stages for a specified reflux ratio
For the speci fi ed recovery of l i ght and heavy key components, DSTWU esti mates:
Mi ni mum refl ux rati o
Mi ni mum number of theoreti cal stages
DSTWU then esti mates one of the fol l owi ng:
Requi red refl ux rati o for the speci fi ed number of theoreti cal stages
Requi red number of theoreti cal stages for the speci fi ed refl ux rati o
DSTWU al so esti mates the opti mum feed stage l ocati on and the condenser and
reboi l er duti es. DSTWU can produce tabl es and pl ots of refl ux rati o versus
number of stages.
Flowsheet Connectivity for DSTWU
Heat
(optional)
Heat
(optional)
Heat
(optional)
Heat
(optional)
Water
(optional)
Distillate
Feed
Bottoms
1
2
N-1
N
Versi on 10
Columns
Material Streams
Inlet One materi al feed stream
Outlet One di sti l l ate stream
One bottoms stream
One water decant stream from condenser (opti onal )
Heat Streams
Inlet One stream for condenser cool i ng (opti onal )
One stream for reboi l er heati ng (opti onal )
Outlet One stream for condenser cool i ng (opti onal )
Each outl et heat stream contai ns the net heat duty for ei ther the condenser or the
reboi l er. The net heat duty i s the i nl et heat stream mi nus the actual (cal cul ated)
heat duty.
I f you use heat streams for the reboi l er, you must al so use them for the
condenser.
Specifying DSTWU
Use the I nput Speci fi cati ons sheet to enter col umn speci fi cati ons. The fol l owi ng
tabl e shows the speci fi cati ons and what i s cal cul ated based on them:
Specification Result
Recovery of light and heavy key components Minimum reflux ratio and minimum number of theoretical stages
Number of theoretical stages Required reflux ratio
Reflux ratio Required number of theoretical stages
DSTWU al so esti mates the opti mum feed stage l ocati on, and the condenser and
reboi l er duti es.
DSTWU can generate an opti onal tabl e of refl ux rati o versus number of stages.
Use the I nput Cal cul ati onOpti ons sheet to enter speci fi cati ons for the tabl e.
Versi on 10
Chapter 4
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for DSTWU:
Input Specify configuration and calculation options, block-specific report options, flash
convergence parameters, valid phases, and DSTWU convergence parameters
Results View summary results, material and energy balance results, and reflux ratio profile
Versi on 10
Columns
Distl
Shortcut Distillation Rating
Di stl si mul ates mul ti stage mul ti component col umns wi th a feed stream and two
product streams.
Di stl performs shortcut di sti l l ati on rati ng cal cul ati ons for a si ngl e-feed, two-
product di sti l l ati on col umn. The col umn can have ei ther a parti al or total
condenser. Di stl cal cul ates product composi ti on usi ng the Edmi ster approach. Di stl
assumes constant mol e overfl ow and constant rel ati ve vol ati l i ti es.
Flowsheet Connectivity for Distl
Heat
(optional)
Heat
(optional)
Heat
(optional)
Heat
(optional)
Water
(optional)
Distillate
Feed
Bottoms
1
2
N-1
N
Material Streams
One bottoms stream
One water decant stream from condenser (opti onal )
Heat Streams
Inlet One stream for condenser cool i ng (opti onal )
Outlet One stream for condenser cool i ng (opti onal )
Versi on 10
Chapter 4
Each outl et heat stream contai ns the net heat duty for ei ther the condenser or the
reboi l er. The net heat duty i s the i nl et heat stream mi nus the actual (cal cul ated)
heat duty.
I f you use heat streams for the reboi l er, you must al so use them for the
condenser.
Specifying Distl
Use the I nput Speci fi cati ons sheet to enter the number of stages, refl ux rati o,
di sti l l ate to feed rati o, and other col umn speci fi cati ons.
Use the I nput Convergence sheet to overri de defaul t val i d phases for condenser,
convergence parameters for fl ash cal cul ati ons, and model convergence parameters.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Di stl :
Input Specify basic column configuration, operating conditions, Distl convergence parameters, and flash
convergence parameters
BlockOptions Override global values for physical properties, simulation options, diagnostic message levels, and
report options for this block
Results View summary of column results and material and energy balance results
Dynamic Specify parameters for dynamic simulation
Versi on 10
Columns
SCFrac
Shortcut Distillation for Complex Columns
Use SCFrac to si mul ate compl ex di sti l l ati on col umns wi th a si ngl e feed, opti onal
stri ppi ng steam, and any number of products. SCFrac al so esti mates the number
of theoreti cal stages and the heati ng/cool i ng duty for each secti on.
SCFrac can model compl ex col umns, such as crude uni ts and vacuum towers.
SCFrac performs shortcut di sti l l ati on cal cul ati ons for col umns wi th a si ngl e feed,
one opti onal stri ppi ng steam stream, and any number of products. SCFrac
di vi des a col umn wi th n products i nto n 1 secti ons. These secti ons are
numbered from the top down. SCFrac assumes:
Rel ati ve vol ati l i ti es are constant for each secti on
The fl ow of l i qui d from secti on to secti on i s negl i gi bl e
SCFrac does not handl e sol i ds. SCFrac can perform free-water cal cul ati ons i n the
condenser.
Flowsheet Connectivity for SCFrac
Steam
(optional)
Distillate
Bottoms
Side Products
(any number)
Feed
Material Streams
One opti onal stri ppi ng steam stream (used for al l secti ons)
One bottoms stream
At l east one si de product stream
Versi on 10
Chapter 4
Specifying SCFrac
SCFrac di vi des an nproduct col umn i nto n 1 secti ons (see the next fi gure,
SCFrac Mul ti draw Col umn). SCFrac numbers the col umn secti ons from the top
down. For each secti on, you must speci fy:
Product pressure
Esti mate of product fl ow or fl ow fracti on based on feed fl ow
You must speci fy the rati o of steam to product fl ow rate for al l product streams
except the di sti l l ate. You must al so enter 2(n 1) speci fi cati ons from the fol l owi ng:
Fracti onati on i ndex (number of theoreti cal stages at total refl ux) of a secti on
Total fl ow, fl ow rate, or recovery of any group of components for a product
stream
Val ue of a property set property for a product stream (see ASPEN PLUS User
Guide, Chapter 28)
Di fference of any pai r of property set properti es for one or a pai r of product
stream(s)
Rati o of any pai r of property set properti es for one or a pai r of product
stream(s)
Because SCFrac performs steam cal cul ati ons, water must al ways be present. Al l
water fl ow l eaves wi th the top product stream.
A Multidraw
Column
P1
P2
P3
P4
P5
Stream-1
P1
P2
Stream-1
P3
Stream-2
P4
P5
Stream-3
Stream-4
Stream-2
Stream-3
Stream-4
Feed
Feed
SCFrac Multidraw Column
Versi on 10
Columns
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for SCFrac:
Input Specify operating parameters, valid phases, SCFrac convergence parameters, and
flash convergence parameters
Results View condenser results, material and energy balance results, design specification
results, section profiles, and product summary
Versi on 10
Chapter 4
RadFrac
Rigorous Fractionation
RadFrac i s a ri gorous model for si mul ati ng al l types of mul ti stage vapor-l i qui d
fracti onati on operati ons. These operati ons i ncl ude:
Ordi nary di sti l l ati on
Absorpti on
Reboi l ed absorpti on
Stri ppi ng
Reboi l ed stri ppi ng
Extracti ve and azeotropi c di sti l l ati on
RadFrac i s sui tabl e for:
Two-phase systems
Three-phase systems
Narrow and wi de-boi l i ng systems
Systems exhi bi ti ng strong l i qui d phase noni deal i ty
RadFrac can detect and handl e a free-water phase or other second l i qui d phase
anywhere i n the col umn. RadFrac can handl e sol i ds on every stage.
RadFrac can handl e pumparounds l eavi ng any stage and returni ng to the same
stage or to a di fferent stage.
RadFrac can model col umns i n whi ch chemi cal reacti ons are occurri ng. Reacti ons
can have fi xed conversi ons, or they can be:
Equi l i bri um
Rate-control l ed
El ectrol yti c
RadFrac can al so model col umns i n whi ch two l i qui d phases and chemi cal
reacti ons occur si mul taneousl y, usi ng di fferent reacti on ki neti cs for the two
l i qui d phases. I n addi ti on, RadFrac can model sal t preci pi tati on.
Al though RadFrac assumes equi l i bri um stages, you can speci fy ei ther Murphree
or vapori zati on effi ci enci es. You can mani pul ate Murphree effi ci enci es to match
pl ant performance.
You can use RadFrac to si ze and rate col umns consi sti ng of trays and/or
packi ngs. RadFrac can model both random and structured packi ngs.
Versi on 10
Columns
Flowsheet Connectivity for RadFrac
Bottoms
Product
Products (optional)
Decanters
Return
Boil-Up
Feeds
1
Reflux
Heat (optional)
Heat (optional)
Liquid Distillate
Vapor Distillate
Water Distillate
(optional)
Heat (optional)
Heat
(optional)
Heat
(optional)
Nstage
Bottom Stage
or Reboiler
Heat Duty
Top Stage
or Condenser
Heat Duty
RadFrac can have any number of:
Stages
I nterstage heaters/cool ers
Decanters
Pumparounds
Material Streams
Inlet At l east one i nl et materi al stream
Outlet One vapor or l i qui d di sti l l ate product stream, or both
One water di sti l l ate product stream (opti onal )
One bottoms l i qui d product stream
Up to three si de product streams per stage (opti onal )
Any number of pseudo-product streams (opti onal )
Each stage can have:
Any number of i nl et streams
Up to three outl et streams (one vapor and two l i qui d)
Outl et streams can be parti al or total drawoffs of the stage fl ows.
Decanter outl et streams can return to the stage i mmedi atel y bel ow. Or they can
be spl i t i nto any number of streams, each returni ng to a di fferent user-speci fi ed
stage. Pumparounds can go between any two stages, or to the same stage.
Any number of pseudoproduct streams can represent col umn i nternal fl ows,
pumparound fl ows, and thermosyphon reboi l er fl ows. A pseudoproduct stream
does not affect col umn resul ts.
Versi on 10
Chapter 4
Heat Streams
Inlet One i nl et heat stream per stage (opti onal )
One heat stream per pumparound (opti onal )
Outlet One outl et heat stream per stage (opti onal )
One heat stream per pumparound (opti onal )
RadFrac uses an i nl et heat stream as a duty speci fi cati on for al l stages except the
condenser, reboi l er, and pumparounds. I f you do not gi ve two col umn operati ng
speci fi cati ons on the Setup Confi gurati on sheet, RadFrac uses a heat stream as a
speci fi cati on for the condenser and reboi l er. I f you do not gi ve two speci fi cati ons on
the Pumparounds Speci fi cati ons sheet, RadFrac uses a heat stream as a
speci fi cati on for pumparounds.
I f you gi ve two speci fi cati ons on the Setup Confi gurati on sheet or Pumparounds
Speci fi cati ons sheet, RadFrac does not use the i nl et heat stream as a
speci fi cati on. The i nl et heat stream suppl i es the requi red heati ng or cool i ng.
Use opti onal outl et streams for the net heat duty of the condenser, reboi l er, and
pumparounds. The val ue of the outl et heat stream equal s the val ue of the i nl et
heat stream (i f any) mi nus the actual (cal cul ated) heat duty.
Specifying RadFrac
Thi s secti on descri bes the fol l owi ng topi cs on RadFrac col umn confi gurati on:
Stage Numberi ng
Feed Stream Conventi ons
Col umns Wi thout Condensers or Reboi l ers
Reboi l er Handl i ng
Heater and Cool er Speci fi cati ons
Decanters
Pumparounds
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RadFrac:
Setup Specify basic column configuration and operating conditions
DesignSpecs Specify design specifications and view convergence results
Vary Specify manipulated variables to satisfy design specifications and view final values
HeatersCoolers Specify stage heating or cooling
Pumparounds Specify pumparounds and view pumparound results
continued
Versi on 10
Columns
Pumparounds Hcurves Specify pumparound heating or cooling curve tables and view tabular
results
Decanters Specify decanters and view decanter results
Efficiencies Specify stage, component or sectional efficiencies
Reactions Specify equilibrium, kinetic, and conversion reaction parameters
CondenserHcurves Specify condenser heating or cooling curve tables and view tabular
results
ReboilerHcurves Specify reboiler heating or cooling curve tables and view tabular results
TraySizing Specify sizing parameters for tray column sections and view results
TrayRating Specify rating parameters for tray column sections and view results
PackSizing Specify sizing parameters for packed column sections and view results
PackRating Specify rating parameters for packed column sections and view results
Properties Specify physical property parameters for column sections
Estimates Specify initial estimates for stage temperatures, vapor and liquid flows,
and compositions
Convergence Specify convergence parameters for the column and feed flash
calculations, and block-specific diagnostic message levels
Report Specify block-specific report options and pseudostreams
UserSubroutines Specify user subroutines for reaction kinetics, KLL calculations, tray
sizing and rating, and packing sizing and rating
ResultsSummary View key column results for the overall RadFrac column
Profiles View and specify column profiles
Stage Numbering
RadFrac numbers stages from the top down, starti ng wi th the condenser (or
starti ng wi th the top stage i f there i s no condenser).
Feed Stream Conventions
Use the Setup Streams sheet to speci fy the feed and product stages.
RadFrac provi des three conventi ons for handl i ng feed streams:
Above-Stage
On-Stage
Decanter (for three phase cal cul ati ons onl y)
Versi on 10
Chapter 4
(See the fol l owi ng fi gures, RadFrac Feed Conventi on Above-Stage and RadFrac
Feed Conventi on On-Stage.)
When the feed conventi on i s Above-Stage, RadFrac i ntroduces a materi al stream
between adjacent stages. The l i qui d porti on fl ows to the stage you speci fy. The
vapor porti on fl ows to the stage above. You can i ntroduce a l i qui d feed to the top
stage (or condenser) by speci fyi ng Stage=1. You can i ntroduce a vapor feed to the
bottom stage (or reboi l er) by speci fyi ng Stage= the number of equi l i bri um stages
+ 1. Feed conventi on Decanter i s used onl y i n three-phase cal cul ati ons (Val i d
Phases=Vapor-Li qui d-Li qui d on the Setup Confi gurati on sheet) i nvol vi ng
decanters. You can i ntroduce a feed di rectl y to a decanter attached to a stage
usi ng thi s conventi on.
n - 1
n
Mixed feed
to stage n
Vapor
Liquid
RadFrac Feed Convention Above-Stage
n - 1
n
n + 1
Mixed feed to
stage n
RadFrac Feed Convention On-Stage
When the Feed Conventi on i s On-Stage, both the l i qui d and vapor porti ons of a
feed fl ow to the stage you speci fy.
Versi on 10
Columns
Columns Without Condensers or Reboilers
You can speci fy the col umn confi gurati on on the Setup Confi gurati on sheet.
If the column has no Then specify On sheet
Condenser None for
Condenser
Setup Configuration
Reboiler None for Reboiler Setup Configuration
Reboiler Handling
RadFrac can model two reboi l er types:
Kettl e
Thermosyphon
A kettl e reboi l er i s model ed as the l ast stage i n the col umn on the Setup
Confi gurati on sheet. Sel ect Kettl e for reboi l er. By defaul t, RadFrac uses a kettl e
reboi l er. To speci fy the reboi l er duty, enter Reboi l er Duty as one of the operati ng
speci fi cati ons on the Setup Confi gurati on sheet or l eave i t as a cal cul ated val ue.
A thermosyphon reboi l er i s model ed as a pumparound wi th a heater, from and to
the bottom stage. Sel ect Thermosyphon for Reboi l er on the Setup Confi gurati on
sheet. Enter al l other thermosyphon reboi l er speci fi cati ons on the Setup Reboi l er
sheet.
The next fi gure shows the thermosyphon reboi l er confi gurati on. By defaul t,
RadFrac returns the reboi l er outl et to the l ast stage usi ng the On-Stage feed
conventi on. You can al so use the Reboi l er Return Feed Conventi on on the
Reboi l er sheet to speci fy Above-Stage. Thi s di rects the vapor porti on of the
reboi l er outl et to Stage= the number of equi l i bri um stages - 1.
Reboiler
Bottoms (B)
Nstage - 1
Nstage
Thermosyphon Reboiler
Versi on 10
Chapter 4
The thermosyphon reboi l er model has fi ve rel ated vari abl es:
Pressure
Fl ow rate
Temperature
Temperature change
Vapor fracti on
You must speci fy one of the fol l owi ng:
Temperature
Temperature change
Vapor fracti on
Fl ow rate
Fl ow rate and temperature
Fl ow rate and temperature change
Fl ow rate and vapor fracti on
I f you choose an opti on consi sti ng of two vari abl es, you must speci fy the reboi l er
heat duty on the Setup Confi gurati on sheet. RadFrac treats the val ue you enter
for the reboi l er heat duty as an i ni ti al esti mate.
The reboi l er pressure i s opti onal . I f you do not enter a val ue, RadFrac uses the
bottom stage pressure.
Heater and Cooler Specifications
You can speci fy i nterstage heaters and cool ers i n one of two ways:
Speci fyi ng the duty di rectl y on the HeatersCool ers Si deDuti es sheet
Requesti ng UA cal cul ati ons on the HeatersCool ers Uti l i tyExchangers sheet
I f you speci fy the duty di rectl y on the HeatersCool ers Si deDuti es sheet, enter a
posi ti ve duty for heati ng and a negati ve duty for cool i ng.
I f you request UA cal cul ati ons on the HeatersCool ers Uti l i tyExchangers sheet,
RadFrac cal cul ates the duty and outl et temperature of the heati ng/cool i ng fl ui d
si mul taneousl y wi th the col umn. The UA cal cul ati ons:
Assume the stage temperature i s constant
Use an ari thmeti c average temperature di fference
Assume the heati ng or cool i ng fl ui d does not experi ence any phase change
To request UA cal cul ati ons, speci fy the:
UA
Heati ng or cool i ng fl ui d component
Fl ow and i nl et temperature of the fl ui d
Versi on 10
Columns
You can speci fy the heat capaci ty of the fl ui d di rectl y on the HeatersCool ers
Uti l i tyExchangers sheet or RadFrac can compute i t from a property method. I f
RadFrac computes the heat capaci ty, you must al so enter the pressure and phase
of the heati ng or cool i ng fl ui d. By defaul t, RadFrac cal cul ates the heat capaci ty
usi ng the bl ock property method. But you can al so use a di fferent property
method.
You can al so speci fy the heat l oss for secti ons of the col umn on the
HeatersCool ers HeatLoss sheet.
Decanters
For three-phase cal cul ati ons (Val i d Phases=Vapor-Li qui d-Li qui d on the Setup
Confi gurati on sheet), you can defi ne any number of decanters. Enter decanter
speci fi cati ons on the Decanters form.
For the decanter on the top stage, you must enter the return fracti on of at l east
one of the two l i qui d phases (Fracti on of 1st Li qui d Returned, Fracti on of 2nd
Li qui d Returned on the Decanters Speci fi cati ons sheet). For decanters on other
stages, you must al ways speci fy both Fracti on of 1st Li qui d Returned and
Fracti on of 2nd Li qui d Returned.
You can enter Temperature and Degrees Subcool i ng on the Decanters Opti ons
sheet to model subcool ed decanters. I f you do not speci fy Temperature and
Degrees Subcool i ng, the decanter i s operated at the temperature of the stage to
whi ch the decanter i s attached. I f si de product streams are decanter products,
you cannot speci fy thei r fl ow rates. RadFrac cal cul ates thei r fl ow rates from the
Fracti on of 1st Li qui d Returned and Fracti on of 2nd Li qui d Returned.
By defaul t RadFrac returns decanter streams to the stage i mmedi atel y bel ow.
You can return the decanter streams to any other stage by enteri ng a di fferent
Return Stage number on the Decanters Speci fi cati ons sheet. You can spl i t a
return stream i nto any number of streams by gi vi ng a spl i t fracti on (Spl i t
Fracti on of Total Return for the 1st Li qui d and 2nd Li qui d). Each resul ti ng
stream may go to a di fferent return stage.
When return streams do not go to the next stage, a feed or pumparound must go
to the next stage. Thi s prevents dry stages.
Pumparounds
RadFrac can handl e pumparounds from any stage to the same or any other stage.
Use the Pumparounds form to enter al l pumparound speci fi cati ons.
You must enter the source and desti nati on stage l ocati ons for pumparounds. A
pumparound can be ei ther a parti al or total drawoff of the:
Stage l i qui d
Fi rst l i qui d phase
Versi on 10
Chapter 4
Second l i qui d phase
Vapor phase
You can associ ate a heater or cool er wi th a pumparound. I f the pumparound i s a
parti al drawoff of the stage fl ow, you must enter two of the fol l owi ng
speci fi cati ons:
Fl ow rate
Temperature
Temperature change
Vapor fracti on
Heat Duty
I f the pumparound i s a total drawoff, you must enter one of the fol l owi ng
speci fi cati ons:
Temperature
Temperature change
Vapor fracti on
Heat Duty
Vapor fracti on i s al l owed onl y when Val i d Phases=Vapor-Li qui d or
Vapor-Li qui d-Li qui d.
Use the Pumparounds Speci fi cati ons sheet to enter these operati ng
speci fi cati ons.
Pressure speci fi cati on i s opti onal . The defaul t pumparound pressure i s the same
as the source stage pressure. RadFrac assumes that the pumparound at the
heater/cool er outl et has the same phase condi ti on as the pumparound at the
i nl et. You can overri de the phase condi ti on usi ng the Val i d phases fi el d on
Pumparound Speci fi cati ons sheet.
RadFrac can return the pumparound to a stage usi ng ei ther the:
On-stage opti on
Above-stage opti on (returns the pumparound to the col umn between two
stages)
I n three-phase col umns, RadFrac can al so return the pumparound to a decanter
associ ated wi th a stage. You can sel ect above-stage usi ng the Return opti on fi el d.
RadFrac assumes the pumparound at the heater/cool er outl et has the same
phase condi ti on as the i nl et.
You can use Return-Phase on the Pumparounds Speci fi cati ons sheet to assi gn a
di fferent phase at the heater/cool er outl et. Or you can speci fy Val i d
Phases=VaporLi qui d or Vapor-Li qui d-Li qui d and l et RadFrac determi ne the
return phase condi ti on from the heater/cool er speci fi cati ons.
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Columns
Free-Water and Rigorous Three-Phase Calculations
RadFrac can perform both free-water and ri gorous three-phase cal cul ati ons. (See
ASPEN PLUS Physical Property Methods and Models, Chapter 6.) These
cal cul ati ons are control l ed by opti ons you speci fy on the Setup Confi gurati on sheet.
You can sel ect from three types of cal cul ati ons:
Free water i n the condenser onl y
Free water on any or al l stages
Ri gorous three-phase cal cul ati ons
When you choose free-water cal cul ati ons i n the condenser, onl y free water can be
decanted from the condenser. You cannot use noni deal for the Overal l Loop
convergence method.
Speci fy one of the fol l owi ng on the Setup Confi gurati on sheet:
Valid Phases= On Sheet For
Vapor-Liquid-FreeWaterCondenser Setup
Configuration
Free water in the condenser only
Vapor-Liquid-FreeWaterAnyStage Setup
Configuration
Free water on all stages
Vapor-Liquid-Liquid Setup
Configuration
Rigorous three-phase calculations
For RadFrac cal cul ati ons, you must al so speci fy whi ch stages to test for two
l i qui d phases on the Setup 3-Phase sheet.
When you choose compl etel y ri gorous three-phase cal cul ati ons on al l stages
sel ected, RadFrac makes no assumpti ons about the nature of the two l i qui d
phases. You can associ ate a decanter wi th any stage. You cannot use Sum-Rates
for the Overal l Loop convergence method.
Efficiencies
You can speci fy one of two types of effi ci enci es:
Vapori zati on
Murphree
Vapori zati on effi ci ency i s defi ned as:
Eff
y
K x
i
v i j
i j i j
,
, ,
Versi on 10
Chapter 4
Murphree effi ci ency i s defi ned as:
Eff
y y
K x y
i j
M
i j i j
k j i j i j
,
, ,
, , ,
+
1
1
Where:
K = Equi l i bri um K val ue
x = Li qui d mol e fracti on
y = Vapor mol e fracti on
Eff
v
= Vapori zati on effi ci ency
Eff
M
= Murphree effi ci ency
i = Component i ndex
j = Stage i ndex
To speci fy vapori zati on or Murphree effi ci enci es, enter the number of actual
stages on the Setup Confi gurati on sheet. Then use the Effi ci enci es form to enter
the effi ci enci es.
For three-phase cal cul ati ons, the vapori zati on and Murphree effi ci enci es you
enter appl y equal l y to the fol l owi ng equi l i bri um by defaul t:
Vapor-l i qui d1 (VL1E)
Vapor-l i qui d2 (VL2E)
You can use the Effi ci enci es form to enter separate effi ci enci es for VL1E and
VL2E. You cannot enter separate effi ci enci es for VL1E and VL2E when you
speci fy equi l i bri um reacti ons or when usi ng Murphree effi ci enci es.
You can use any of these effi ci enci es to account for departure from equi l i bri um.
But you cannot convert from one effi ci ency to the other. Magni tudes of the
effi ci enci es can be qui te di fferent. You shoul d mani pul ate the Murphree
effi ci ency to match the operati ng data when:
Effi ci ency i s unknown
Actual col umn operati ng data are avai l abl e
When mani pul ati ng the Murphree effi ci ency, use desi gn speci fi cati ons on the
Desi gnSpecs and Vary forms. Detai l s on usi ng and esti mati ng effi ci enci es are
descri bed by Hol l and, Fundamentals of Multi-Component Distillation, McGraw-
Hi l l Book Company, 1981.
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Columns
Algorithms
You can sel ect an al gori thm and/or i ni ti al i zati on opti on for col umn si mul ati on on
the Convergence Basi c sheet. The defaul t standard al gori thm and standard
i ni ti al i zati on opti on are appropri ate for most appl i cati ons. You can i mprove
convergence behavi or for the fol l owi ng appl i cati ons usi ng the gui del i nes descri bed
i n thi s secti on:
Petrol eum and Petrochemi cal Appl i cati ons
Hi ghl y Noni deal Systems
Azeotropi c Di sti l l ati on
Absorbers and Stri ppers
Cryogeni c Appl i cati ons
To change the al gori thm and i ni ti al i zati on opti on on the Convergence Basi c
sheet, you must fi rst choose Custom as the opti on i n the Convergence fi el d on the
Setup Confi gurati on sheet.
Petroleum and Petrochemical Applications
I n petrol eum and petrochemi cal appl i cati ons i nvol vi ng extremel y wi de-boi l i ng
mi xtures and/or many components and desi gn speci fi cati ons, you can i mprove the
convergence effi ci ency and rel i abi l i ty by choosi ng Sum-Rates i n the Al gori thm fi el d
on the Convergence Basi c sheet.
Highly Nonideal Systems
When l i qui d phase noni deal i ti es are excepti onal l y strong, choose Noni deal i n the
Al gori thm fi el d on the Convergence Basi c sheet to i mprove the convergence
behavi or. Use thi s al gori thm onl y when the number of outsi de l oop i terati ons
(usi ng the standard al gori thm) exceeds 25.
You can al so use the Newton al gori thm for hi ghl y noni deal systems. Newton i s
better for col umns wi th hi ghl y sensi ti ve speci fi cati ons. But i t i s usual l y sl ower,
especi al l y for col umns wi th many stages and components.
Azeotropic Distillation
For azeotropi c di sti l l ati on appl i cati ons where an entrai ni ng agent separates an
azeotropi c mi xture, speci fy the fol l owi ng on the Convergence Basi c sheet:
Al gori thm, Newton
I ni ti al i zati on method, Azeotropi c
A cl assi c exampl e of azeotropi c di sti l l ati on i s ethanol dehydrati on usi ng benzene.
Versi on 10
Chapter 4
Absorbers and Strippers
To model absorbers and stri ppers, speci fy Condenser=None and Reboi l er=None on
the Setup Confi gurati on sheet. The heat duty i s zero for adi abati c operati on. For
extremel y wi de-boi l i ng mi xtures, speci fy one of the fol l owi ng:
Al gori thm=Sum-Rates on the Convergence Basi c sheet
Convergence=Standard on the Setup Confi gurati on sheet and choose
Absorber=Yes on the Convergence Basi c sheet
Cryogenic Applications
For cryogeni c appl i cati ons such as ai r separati on, the standard al gori thm i s
recommended. To i nvoke a speci al i ni ti al i zati on procedure desi gned for cryogeni c
systems, speci fy Cryogeni c for I ni ti al i zati on on the Convergence Basi c sheet.
Rating Mode
RadFrac al l ows the col umn to be operated i n a rati ng mode or a desi gn mode.
Rati ng mode requi res di fferent col umn speci fi cati ons for two- and three-phase
cal cul ati ons.
For two-phase cal cul ati ons, you must enter the fol l owi ng on the Setup Form:
Val i d Phases=Vapor-Li qui d or Vapor-Li qui d-FreeWaterCondenser for
handl i ng free water i n condenser
A Total , Subcool ed, or Parti al -Vapor condenser
Two addi ti onal col umn operati ng vari abl es
I f the condenser or refl ux i s subcool ed, you can al so speci fy the degrees
subcool i ng or the subcool ed temperature.
For three-phase cal cul ati ons, you must speci fy Val i d Phases= Vapor-Li qui d-
Li qui d or Vapor-Li qui d-FreeWaterAnyStage (for free water cal cul ati ons) on the
Setup Confi gurati on sheet. The requi red speci fi cati ons depend on what you
speci fy for the return fracti ons of the two l i qui d phases (Fracti on of 1st Li qui d
Returned and Fracti on of 2nd Li qui d Returned) i n the top stage decanter. The
fol l owi ng tabl e l i sts the three speci fi cati on opti ons:
If you specified this on
Decanters Specifications Enter on Setup Configuration
Fraction of 1st Liquid Returned or Fraction
of 2nd Liquid Returned, or no top decanter
A Total, Subcooled, or Partial-Vapor condenser and two operating
specifications
Fraction of 1st Liquid Returned and
Fraction of 2nd Liquid Returned
A Total, Subcooled, or Partial-Vapor condenser and one operating
specification
Fraction of 1st Liquid Returned and
Fraction of 2nd Liquid Returned
Two operating specifications, and an estimate for the amount of vapor in the
distillate on the Estimates Vapor Composition sheet. RadFrac assumes a
partial condenser with both vapor and liquid distillates.
Versi on 10
Columns
Design Mode
RadFrac al l ows the col umn to be operated i n rati ng mode or desi gn mode. I n desi gn
mode, use the Desi gnSpecs form to speci fy col umn performance parameters (such
as puri ty or recovery). You must i ndi cate whi ch vari abl es to mani pul ate to achi eve
these speci fi cati ons. You can mani pul ate any vari abl es that are al l owed i n rati ng
mode, except:
Number of stages
Pressure profi l e
Vapori zati on effi ci ency
Subcool ed refl ux temperature
Degrees of subcool i ng
Decanter temperature and pressure
Locati ons of feeds, products, heaters, pumparounds, and decanters
Pressures of thermosyphon reboi l er and pumparounds
UA speci fi cati ons for heaters
The fl ow rates of i nl et materi al streams and the duti es of i nl et heat streams can
al so be mani pul ated vari abl es.
These are the desi gn speci fi cati ons:
You can specify For any
Purity Stream including internal streams
Recovery of any components groups Set of product streams, including sidestreams
Flow rate of any components groups Internal stream or set of product streams
Temperature Stage
Value of any Prop-Set property Internal or product stream
Ratio or difference of any pair of

Prop-Set properties
Single or paired internal or product streams
Flow ratio of any components groups to any
other component groups
Internal streams to any other internal streams, or to any set of feed or product
streams
Express the purity as the sum of mole, mass, or standard liquid volume fractions of any group of
components relative to any other group of components.
Express recovery as a fraction of the same components in any set of feed streams.
See ASPEN PLUS User Gui de.

Versi on 10
Chapter 4
Reactive Distillation
RadFrac can handl e chemi cal reacti ons. These reacti ons can occur i n the l i qui d
and/or vapor phase. The detai l s about the reacti ons are entered on a generi c
Reacti ons form outsi de RadFrac. RadFrac al l ows two di fferent reacti on model
types: REAC-DI ST or USER. RadFrac can model the fol l owi ng types of reacti ons:
Equi l i bri um-control l ed
Rate-control l ed
Conversi on
El ectrol yti c
RadFrac can al so model sal t preci pi tati on, especi al l y i n the case of el ectrol yti c
systems. You can request reacti on cal cul ati ons for the enti re col umn, or you can
restri ct reacti ons to a certai n col umn segment (for exampl e, to model the
presence of catal yst). For three-phase cal cul ati ons, you can restri ct reacti ons to
one of the two l i qui d phases, or use separate reacti on ki neti cs for the two l i qui d
phases.
To i ncl ude reacti ons i n RadFrac you must enter the fol l owi ng i nformati on on the
Reacti ons Speci fi cati ons sheet:
Reacti on type and Reacti on/Chemi stry I D
Col umn secti on i n whi ch the reacti ons occur
Dependi ng on the reacti on type, you must enter equi l i bri um constant, ki neti c, or
conversi on parameters on the generi c Reacti ons form outsi de RadFrac. For
el ectrol yti c reacti ons, you can al so enter the reacti on data on the Reacti ons
Chemi stry form outsi de RadFrac. To consi der sal t preci pi tati on, enter the sal t
preci pi tati on parameters on the Reacti ons Sal t sheet or the Reacti ons Chemi stry
form outsi de RadFrac.
To associ ate reacti ons and sal t preci pi tati on wi th a col umn segment, enter the
correspondi ng Reacti ons I D (or Chemi stry I D) on the Reacti ons Speci fi cati ons
sheet.
For rate-control l ed reacti ons, you must enter hol dup or resi dence ti me data i n
the phase where the reacti ons occur. Use the Reacti ons Hol dups or Resi dence
Ti mes sheets. For conversi on reacti ons, use the Reacti ons Conversi on sheet to
overri de the conversi on parameters speci fi ed on the Reacti ons Conversi on form.
RadFrac al so supports User Reacti on Subrouti ne. The name and other detai l s of
the reacti on subrouti ne are entered on the UserSubrouti nes form.
Solution Strategies
RadFrac uses two general approaches for col umn convergence:
I nsi de-out
Napthal i -Sandhol m
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Columns
The standard, sum-rates, and noni deal al gori thms are vari ants of the i nsi de-out
approach. The Mul ti Frac, PetroFrac, and Extract model s al so use thi s approach.
The Newton al gori thm uses the cl assi cal Napthal i -Sandhol m approach. Use the
Convergence form to sel ect the al gori thm and speci fy the associ ated parameters.
Inside-Out Algorithms
The i nsi de-out al gori thms consi st of two nested i terati on l oops.
The K-val ue and enthal py model s you speci fy are eval uated onl y i n the outsi de
l oop to determi ne parameters of si mpl i fi ed l ocal model s. When usi ng noni deal ,
al gori thm RadFrac i ntroduces a composi ti on dependence i nto the l ocal model s.
The l ocal model parameters are the outsi de l oop i terati on vari abl es. The outsi de
l oop i s converged when the changes of the outsi de l oop i terati on vari abl es are
suffi ci entl y smal l from one i terati on to the next. Convergence uses a combi nati on
of the bounded Wegstei n method and the Broyden quasi -Newton method for
sel ected vari abl es.
I n the i nsi de l oop, the basi c descri bi ng equati ons (component mass bal ances,
total mass bal ance, enthal py bal ance, and phase equi l i bri um) are expressed i n
terms of the l ocal physi cal property model s. RadFrac sol ves these equati ons to
obtai n updated temperature and composi ti on profi l es. Convergence uses one of
the fol l owi ng methods:
Bounded Wegstei n
Broyden quasi -Newton
Schubert quasi -Newton
Newton
RadFrac adjusts the i nsi de l oop convergence tol erance wi th each outsi de l oop
i terati on. The tol erance becomes ti ghter as the outsi de l oop converges.
Newton Algorithm
The Newton al gori thm sol ves col umn-descri bi ng equati ons si mul taneousl y, usi ng
Newtons method. The convergence i s stabi l i zed usi ng the dogl eg strategy of
Powel l . Desi gn speci fi cati ons may be sol ved ei ther si mul taneousl y wi th the col umn-
descri bi ng equati ons or i n an outer l oop.
Design Mode Convergence
RadFrac provi des two methods for handl i ng desi gn speci fi cati on convergence:
Nested convergence
Si mul taneous convergence
Versi on 10
Chapter 4
Nested Design Spec Convergence (for all algorithms
except SUM-RATES)
The Nested Mi ddl e Loop convergence method attempts to sati sfy the desi gn
speci fi cati ons by determi ni ng the val ues of the mani pul ated vari abl es (wi thi n
thei r bounds) that mi ni mi ze the wei ghted sum of squares functi on:

_
,
Wm
Gm GM
G
m m
*
2
Where:
m
= Desi gn speci fi cati on number
G
= Cal cul ated val ue

G
= Desi red val ue
G*
= Scal i ng factor
w
= Wei ghti ng factor
The al gori thm that mani pul ates the vari abl es to mi ni mi ze does not depend on
matchi ng parti cul ar vari abl es wi th correspondi ng desi gn speci fi cati ons. You
shoul d careful l y sel ect the mani pul ated vari abl es and desi gn speci fi cati ons. Make
sure that each mani pul ated vari abl e has a si gni fi cant effect on at l east one
desi gn speci fi cati on.
The number of desi gn speci fi cati ons must be equal to or greater than the number
of mani pul ated vari abl es. I f there are more desi gn speci fi cati ons than
mani pul ated vari abl es, assi gn wei ghti ng factors to refl ect the rel ati ve i mportance
of the speci fi cati ons. The l arger the wei ghti ng factor, the more nearl y a
speci fi cati on wi l l be sati sfi ed. Scal e factors normal i ze the errors, so that di fferent
speci fi cati on types are compared on a consi stent basi s.
When a val ue of a mani pul ated vari abl e reaches a bound, that bound i s acti ve. I f
a probl em has no acti ve bounds and the same number of mani pul ated vari abl es
as desi gn speci fi cati ons, then wi l l approach zero (wi thi n some tol erance) when
al l speci fi cati ons are sati sfi ed.
I f there are acti ve bounds or more desi gn speci fi cati ons than mani pul ated
vari abl es, RadFrac mi ni mi zes . The wei ghti ng factors determi ne the rel ati ve
degree to whi ch the desi gn speci fi cati ons are sati sfi ed.
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Columns
Simultaneous Design Spec Convergence (for
Algorithm=SUM-RATES, NEWTON)
The Si mul taneous Mi ddl e Loop convergence method al gori thm sol ves the desi gn
speci fi cati on functi ons si mul taneousl y wi th the col umn-descri bi ng equati ons:
Fm
Gm GM
G
m
_
,
*
0
Because the Si mul taneous Mi ddl e Loop convergence method uses an equati on-
sol vi ng approach, there must be an equal number of desi gn speci fi cati ons and
mani pul ated vari abl es. I n the nested method, no coupl i ng i s assumed between
desi gn speci fi cati ons and mani pul ated vari abl es. However, each desi gn
speci fi cati on must be si gni fi cantl y affected by at l east one mani pul ated vari abl e.
Bounds and wei ghti ng factors are not used. I n general , the Si mul taneous method
gi ves better performance i f al l the speci fi cati ons are feasi bl e.
Physical Properties
To overri de the gl obal physi cal property method, use the Properti es
PropertySecti ons sheet. You can speci fy di fferent physi cal properti es for di fferent
parts of the col umn.
For three-phase cal cul ati ons, you can speci fy separate cal cul ati on methods for
Vapor-Li qui d1 Equi l i bri um (VL1E) and Li qui d1-Li qui d2 Equi l i bri um (LLE). Use
one of the fol l owi ng methods:
Associ ate separate property methods wi th VL1E and LLE usi ng the Phase
Equi l i bri um l i st box
Cal cul ate VL1E usi ng a property method. Speci fy LLE usi ng l i qui d-l i qui d
di stri buti on (KLL) coeffi ci ents
You can use the Properti es KLLSecti ons sheet to enter the KLL coeffi ci ents usi ng
a bui l t-i n temperature pol ynomi al , and associ ate the coeffi ci ents wi th one or
more col umn segments. Or you can use the Properti es KLLCorrel ati ons sheet to
associ ate a user-KLL subrouti ne wi th one or more col umn segments.
Solids Handling
RadFrac has two methods for handl i ng i nert sol i ds:
Overal l -bal ance
Stage-by-stage
Versi on 10
Chapter 4
Use the Sol i ds handl i ng opti on on the Convergence Basi c sheet to sel ect ei ther an
overal l bal ance or stage-by-stage. The two methods di ffer i n how they treat sol i ds
i n the mass and energy bal ances. Nei ther method consi ders i nert sol i ds i n the
phase equi l i bri um cal cul ati ons. However, sal ts formed by sal t preci pi tati on
reacti ons (see Reacti ve Di sti l l ati on) are consi dered i n phase equi l i bri um
cal cul ati ons.
The overal l -bal ance method:
Temporari l y removes al l sol i ds from i nl et streams
Performs col umn cal cul ati ons wi thout sol i ds
Adi abati cal l y mi xes sol i ds removed from i nl et streams wi th l i qui d product
from the bottom stage
The overal l -bal ance method mai ntai ns an overal l mass and energy bal ance
around the col umn. But i t does not sati sfy i ndi vi dual stage bal ances. Thi s i s the
defaul t method.
The stage-by-stage method treats sol i ds ri gorousl y i n al l stage mass and energy
bal ances. The rati o of l i qui ds to sol i ds on a stage i s mai ntai ned i n the product
streams wi thdrawn from that stage. The speci fi ed product fl ow i s the total fl ow
rate of the stream, i ncl udi ng the sol i ds. I f a nonconventi onal (NC) sol i ds
substream i s present i n the col umn feeds, you must gi ve al l col umn fl ow and fl ow
rati o speci fi cati ons on a mass basi s.
When you speci fy a decanter, RadFrac can decant the sol i ds parti al l y or total l y.
By defaul t, RadFrac decants the sol i ds parti al l y al ong wi th the second l i qui d
phase. RadFrac uses the return fracti on you speci fy for the second l i qui d phase
(Fracti on of 2nd Li qui d Returned on the Decanters Speci fi cati ons sheet) to decant
the sol i ds. I f there i s no second l i qui d phase i n the decanter, RadFrac decants the
sol i ds parti al l y al ong wi th the fi rst l i qui d phase. RadFrac uses the return
fracti on you speci fy for the fi rst l i qui d phase (Fracti on of 2nd Li qui d Returned on
the Decanters Speci fi cati ons sheet) i n thi s case. You can request compl ete
decanti ng of the sol i ds by sel ecti ng Decant Sol i ds Total l y on the Decanters
Opti ons sheet.
Versi on 10
Columns
MultiFrac
Mul ti Frac i s a ri gorous model for si mul ati ng general systems of i nterl i nked
mul ti stage fracti onati on uni ts. Mul ti Frac model s can handl e a compl ex
confi gurati on consi sti ng of:
Any number of col umns, each wi th any number of stages
Any number of connecti ons between col umns or wi thi n each col umn
Arbi trary fl ow spl i tti ng and mi xi ng of connecti ng streams
Mul ti Frac can handl e operati ons wi th:
Si de stri ppers
Pumparounds
External heat exchangers
Si ngl e-stage fl ashes
Feed furnace
Typi cal Mul ti Frac appl i cati ons i ncl ude:
Heat-i nterstaged col umns, such as Petl yuk towers
Ai r separati on col umn systems
Absorber/stri pper combi nati ons
Ethyl ene pl ant pri mary fracti onator/quench tower combi nati ons
You can al so use Mul ti Frac for petrol eum refi ni ng fracti onati on uni ts such as
atmospheri c crude uni ts and vacuum uni ts. But for these appl i cati ons, PetroFrac
i s more conveni ent to use. Use Mul ti Frac onl y when the confi gurati on i s beyond
the capabi l i ti es of PetroFrac.
Mul ti Frac can detect a free-water phase i n the condenser or anywhere i n the
col umn. I t can decant the free-water phase on any stage.
Al though Mul ti Frac assumes equi l i bri um stage cal cul ati ons, you can speci fy
ei ther Murphree or vapori zati on effi ci enci es.
You can use Mul ti Frac for both si zi ng and rati ng trays and packi ngs. Mul ti Frac
can model both random and structured packi ngs.
Versi on 10
Chapter 4
Flowsheet Connectivity for MultiFrac
Nstage
Top Stage
or Condenser
Heat Duty
(optional)
Feeds
Heat
Heat
Heat (optional)
Vapor Distillate
Side Products (optional)
Interconnecting Streams
(Heater Optional)
Bottoms
(or Interconnecting
Stream)
Liquid Distillate (optional)
Water Distillate (optional)
Pumparounds
and Bypasses
(Heater Optional)
Bottom Stage or
Reboiler Heat Duty
(optional)
(Heater Optional)
Heat (optional)
Top Stage
or Condenser
Heat Duty
(optional)
Feeds
Heat
Heat
Heat (optional)
Vapor Distilate
Side Products (optional)
(Heater Optional)
Bottoms
(or Interconnecting
Stream)
Pumparounds
and Bypasses
(Heater Optional)
Bottom Stage or
Reboiler Heat Duty
(optional)
(Heater Optional)
Heat (optional)
Reflux
1
1
Nstage
Nstage
Versi on 10
Columns
Material Streams
Outlet Any number of opti onal pseudo-product streams
Up to three opti onal outl et materi al streams per stage (one vapor, one
l i qui d, and one free water)
You can connect any number of col umns by any number of connecti ng streams. For
each col umn, any number of connecti ng streams can represent pumparounds and
bypasses. These streams can fl ow between any two stages, or to the same stage.
Each connecti ng stream can have an associ ated heater.
Each col umn must have one l i qui d product or connecti ng stream l eavi ng the
bottom stage. The top stage of the mai n col umn (col umn 1) must have a product
stream, whi ch cannot be a connecti ng stream. The top stage of the other col umns
(col umn 2, 3, ...) must have a vapor product or a vapor connecti ng stream.
The pseudoproduct streams represent col umn i nternal fl ows and connecti ng
stream fl ows.
Heat Streams
Inlet One i nl et heat stream per stage (opti onal )
One i nl et heat stream per connecti ng stream (opti onal )
Outlet One outl et heat stream per connecti ng stream (opti onal )
Mul ti Frac uses an i nl et heat stream as a duty speci fi cati on for al l stages except the
condenser, reboi l er, and connecti ng streams. I f you do not provi de two col umn
operati ng speci fi cati ons on the Col umns Setup Confi gurati on sheet, Mul ti Frac uses
a heat stream as a speci fi cati on for the condenser and reboi l er.
I f you do not provi de two speci fi cati ons on the ConnectStreams form, Mul ti Frac
uses a heat stream as a speci fi cati on for connecti ng streams.
I f you provi de two speci fi cati ons on the Col umns Setup Confi gurati on sheet or
ConnectStreams form, Mul ti Frac does not use the i nl et heat stream as a
You can use opti onal outl et heat streams for the net heat duty of the condenser,
reboi l er, and connecti ng streams. The val ue of the outl et heat stream equal s the
val ue of the i nl et heat stream (i f any), mi nus the actual (cal cul ated) heat duty.
Versi on 10
Chapter 4
Specifying MultiFrac
I ndi vi dual col umns are i denti fi ed by col umn numbers. The numberi ng order does
not affect al gori thm performance. Col umn 1 has di fferent speci fi cati ons from the
other col umns. Wi thi n each col umn, the stages are numbered from the top down,
starti ng wi th the condenser.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Mul ti Frac:
Columns Setup Specify basic column configuration and operating conditions
Columns HeatersCoolers Specify interstage heaters/coolers
Columns FlowSpecs Specify liquid and vapor flow specifications
Columns Efficiencies Specify stage or component efficiencies
Columns Properties Specify physical property parameters for column sections
Columns Estimates Specify initial estimates for stage temperatures, and vapor and liquid flows and
compositions
Columns Results View column summary
Columns Profiles View column profiles
InletsOutlets Specify inlet and outlet material and heat stream locations
ConnectStreams Specify sources and destinations of connecting material and heat streams, view connecting
stream results
FlowRatios Specify stream flow ratios
DesignSpecs Specify design specifications, and view convergence results
CondenserHcurves Specify condenser heating or cooling curve tables and view tabular results
ReboilerHCurves Specify reboiler heating or cooling curve tables and view tabular results
ConnectStreamHCurves Specify connecting stream heating or cooling curve tables and view tabular results
TraySizing Specify sizing parameters for tray column sections, and view results
TrayRating Specify rating parameters for tray column sections, and view results
PackSizing Specify sizing parameters for packed column sections, and view results
PackRating Specify rating parameters for packed column sections, and view results
Convergence Specify convergence parameters for column calculations, and block-specific diagnostic
message levels
Report Specify block-specific report options and pseudostream information
UserSubroutines Specify user subroutine parameters for tray sizing and rating, and packing sizing and rating
ResultsSummary View results of balances and splits
Versi on 10
Columns
Stream Definitions
Mul ti Frac uses four types of streams:
External streams
Connecti ng streams
I nternal streams
Pseudostreams
External streams are standard Mul ti Frac i nl et and outl et streams. They are
i denti fi ed by stream I Ds.
Connecti ng streams are wi thi n Mul ti Frac but external to i ndi vi dual col umns.
They can connect two col umns, or stages of the same col umn (bypasses and
pumparounds). You can associ ate a heater wi th any connecti ng stream.
Connecti ng stream heaters are i denti fi ed by connecti ng stream numbers.
I nternal streams are l i qui d or vapor fl ows between adjacent stages of the same
col umn. An i nternal stream i s i denti fi ed by a source stage number and a col umn
number.
Pseudostreams store the resul ts of i nternal and connecti ng streams. They are a
subset of external outl et streams. Unl i ke normal outl et streams, pseudostreams
do not parti ci pate i n bl ock mass bal ance cal cul ati ons.
Required Specifications
Fol l ow these gui del i nes when enteri ng speci fi cati ons for col umn 1:
The number of stages must be greater than 1
Two addi ti onal operati ng speci fi cati ons are requi red
The di sti l l ate fl ow may not be a connecti ng stream
You must speci fy:
Bottoms rate or di sti l l ate rate. The di sti l l ate rate i ncl udes both the vapor and
l i qui d di sti l l ate fl ows
Ei ther condenser duty, reboi l er duty, refl ux rati o or refl ux rate
Di sti l l ate vapor fracti on or condenser temperature
I f you speci fy the condenser stage temperature:
Both l i qui d and vapor di sti l l ate products must be present (di sti l l ate vapor
fracti on i s greater than 0 or l ess than 1)
You must al so speci fy an esti mate for the di sti l l ate vapor fracti on
Versi on 10
Chapter 4
Fol l ow these gui del i nes when enteri ng speci fi cati ons for other col umns:
The number of stages can be 1 (for exampl e, to model a si ngl e-stage fl ash or
feed furnace)
The di sti l l ate can be a connecti ng stream
Mul ti Frac cal cul ates the di sti l l ate vapor fracti on
The di sti l l ate rate i ncl udes onl y the vapor di sti l l ate fl ow and must be greater
than zero. I f a l i qui d di sti l l ate i s present, speci fy fl ow on the I nl etsOutl ets
form.
For col umns wi th more than one stage, you may speci fy condenser duty, reboi l er
duty, bottoms rate, di sti l l ate rate, and refl ux rate.
For col umns wi th one stage, you must speci fy ei ther:
Bottoms rate
Di sti l l ate rate (i ncl udes onl y the vapor di sti l l ate)
Condenser duty
Feed Stream Conventions
Mul ti Frac provi des two conventi ons for handl i ng feed streams (see Mul ti Frac Feed
Conventi on Above-Stage and Mul ti Frac Feed Conventi on On-Stage i n the fol l owi ng
fi gures):
Above-Stage
On-Stage
When Feed-Conventi on i s Above-Stage, Mul ti Frac i ntroduces a materi al stream
between adjacent stages. The l i qui d porti on fl ows to the stage (n) you speci fy. The
vapor porti on fl ows to the stage above (n 1). You can i ntroduce a l i qui d feed to
the top stage (or condenser) by speci fyi ng Stage=1. You can i ntroduce a vapor
feed to the bottom stage (or reboi l er) by speci fyi ng Stage=Number of stages + 1.
Vapor
Liquid
n - 1
Mixed feed
to stage n
MultiFrac Feed Convention Above-Stage
Versi on 10
Columns
n - 1
n + 1
n
Mixed feed
to stage n
MultiFrac Feed Convention On-Stage
When Feed-Conventi on i s On-Stage, both the l i qui d and vapor porti ons of a feed
fl ow to the stage (n) you speci fy.
Connecting Streams
Mul ti Frac al l ows any number of connecti ng streams. Any number of these streams
can have the same:
Source col umn, stage, and phase
Desti nati on col umn and stage
Mul ti Frac i ntroduces connecti ng streams on the desti nati on stage regardl ess of
thei r phase (that i s, Feed Conventi on=On-Stage). Al l connecti ng streams can
have a heater wi th heat duty, temperature, or temperature change speci fi ed. Use
the ConnectStreams form to enter al l speci fi cati ons for connecti ng streams.
Each termi nal stream can be the source of a product stream and any number of
connecti ng streams. I f there i s no product stream, at l east one connecti ng stream
must have an unspeci fi ed fl ow.
For a connecti ng stream, requi red speci fi cati ons depend on whether the stream:
Has a fl ow rate that i s fi xed i ndi rectl y on the Fl owRati os or Col umns
Fl owSpecs form
I s a termi nal stream
I s a pumparound to the top stage of col umn 1
Versi on 10
Chapter 4
For this type of connecting
stream You must specify
One that does not satisfy the
above conditions
Two of the following: flow, temperature (or temperature change), and duty
One whose flow is fixed

indirectly on the FlowRatios or
Columns FlowSpecs form
Either temperature (or temperature change), or duty
A terminal stream (vapor

distillate or liquid bottoms)
Either temperature (or temperature change) or duty
Duty can default to 0 if necessary.

You can enter a second speci fi cati on. I f thi s speci fi cati on i s mi ssi ng, Mul ti Frac
uses the net fl ow from the stage excl udi ng any other connecti ng stream wi th fl ow
speci fi cati ons.
For a connecti ng stream that i s the l i qui d pumparound to the top stage of col umn
1, enter two of the fol l owi ng:
Fl ow
Temperature (or temperature change)
Duty (speci fy 0 i f there i s no associ ated heater or cool er)
I f you enter onl y one of fl ow, temperature, or temperature change, Mul ti Frac
uses the top stage duty for the mi ssi ng requi rement.
When a stage i s the desti nati on of a connecti ng stream, Mul ti Frac uses the heat
duty associ ated wi th the stage to determi ne the temperature of the connecti ng
stream. When you enter the duty, temperature, or temperature change of the
connecti ng stream, the stage duty does not affect the connecti ng stream
temperature. Stage duty i s properl y accounted for i n the stage enthal py
cal cul ati ons.
When a pumparound, bypass, or other connecti ng stream has a speci fi ed
temperature change or outl et temperature, Mul ti Frac assumes that the speci fi c
val ue does not resul t i n a phase change of any fracti on of the stream. When you
speci fy heat duty, a phase change may occur.
Connecti ng streams can be ei ther a total or parti al drawoff of the stage fl ow.
Mul ti Frac determi nes the drawoff type based on the number of speci fi cati ons you
gi ve.
If the drawoff type is You enter
Partial Two of the following: flow, temperature, temperature change, and heat duty
Total One of the following: temperature, temperature change, and heat duty
Enter zero for heat duty if heater is absent.
Flow rate is taken as the net flow of the stage, excluding any product flow and any other connecting
stream flow.
Versi on 10
Columns
Mul ti Frac al l ows total drawoff onl y for the top vapor stream and bottom l i qui d
stream. For parti al drawoffs you can speci fy the fl ow rate. Or Mul ti Frac can
determi ne the fl ow rate based on one of the fol l owi ng:
Another fl ow speci fi cati on (Col umns Fl owSpecs form)
A fl ow rati o speci fi cati on (Fl owRati os form)
I f you enter onl y one speci fi cati on for pumparounds to the top stage of the mai n
col umn, Mul ti Frac uses the top stage heat duty as the second speci fi cati on.
When a connecti ng stream has a speci fi ed temperature or temperature change,
Mul ti Frac assumes the speci fi ed val ue does not resul t i n a phase change of any
fracti on of the stream. When you speci fy the heat duty, a phase change can occur.
Heaters
Use the Col umns HeatersCool ers form to enter heater stage l ocati ons and duti es.
You can speci fy heaters i ndi rectl y by choosi ng a heater duty as the adjusted
vari abl e i n one of the fol l owi ng forms:
Form Used to specify
Columns FlowSpecs Stage liquid or vapor flow rate
FlowRatios Vapor-to-liquid flow ratio
Flow Rate Specifications
You can use the Col umns Fl owSpecs form to speci fy any stage l i qui d and vapor
fl ow rates. The val ue you speci fy refers to the net fl ow of the stage l i qui d or vapor
fl ow. Thi s val ue excl udes any porti ons wi thdrawn by si de products and other
connecti ng streams wi th fl ow speci fi cati ons. Thi s feature i s typi cal l y used for
speci fyi ng:
I nternal refl ux rate or total i nternal drawoff
Overfl ash i n refi ni ng appl i cati ons
Boi l up rate
For a termi nal stream, fl ow speci fi cati ons refer to the net fl ow of the stream
excl udi ng any porti on wi thdrawn by connecti ng streams wi th fl ow speci fi cati ons.
Fl ow speci fi cati ons i ncl ude:
Speci fi cati ons provi ded on the ConnectStreams form
Speci fi cati ons fi xed by the associ ated heater speci fi cati ons
Another Fl owSpecs or Fl owRati os speci fi cati on
For an i nternal stream, fl ow speci fi cati ons refer to the net fl ow of the stream
excl udi ng any porti ons wi thdrawn as products or connecti ng streams.
Versi on 10
Chapter 4
When you enter a fl ow speci fi cati on, Mul ti Frac adjusts the fl ow rate of a
connecti ng stream or the duty of a heater.
If the adjusted variable is You enter the
A connecting stream flow Connecting stream number in the IC-Stream field
A heater duty Heater column and stage numbers
You can pl ace the cal cul ated heat duty i n an outl et heat stream usi ng the
I nl etsOutl ets form. I ni ti al esti mates for adjusted vari abl es are not requi red.
I f a product or connecti ng stream of the same phase i s l eavi ng the stage, a
speci fi ed val ue may be zero to model a total drawoff .
Mul ti Frac wi l l vary the heat duty associ ated wi th the heater of the same stage or
another stage or the fl ow rate of an associ ated connecti ng stream to sati sfy
enthal py and mass bal ances.
If this will be varied You must specify
Heat duty Q-Column and Stage
Flow rate of a connecting
stream
Stream number (IC-Stream)
Be cauti ous when sel ecti ng the:
Associ ated stage wi th vari ed heat duty
Connecti ng stream wi th vari ed fl ow rate
An i ni ti al guess for the associ ated heat duty i s not requi red.
Versi on 10
Columns
Flow Ratio Specifications
Use the Fl owRati os form to speci fy the rati o of two fl ow rates. The fl ows can be of
di fferent phases, and come from any stage of any col umn. Thi s feature i s typi cal l y
used for speci fyi ng the:
I nternal refl ux rati o
Overfl ash i n refi ni ng appl i cati ons
Boi l up rati o
For a termi nal stream, the fl ows refer to the net fl ow of a stream, excl udi ng any
porti on wi thdrawn by connecti ng streams wi th fl ow speci fi cati ons. Fl ow
speci fi cati ons i ncl ude those:
Speci fi ed on the ConnectStreams form
Fi xed by ei ther the associ ated heater speci fi cati on, another Col umns
Fl owSpecs sheet, or a Fl owRati os Speci fi cati ons sheet)
For an i nternal stream, the fl ows refer to the net fl ow of the stream, excl udi ng
any porti on wi thdrawn as products or connecti ng streams. When you speci fy a
fl ow rati o, these wi l l be vari ed to sati sfy enthal py and mass bal ances:
Heat duty of the same stage or another stage
Fl ow rate of an associ ated connecti ng stream
When you enter a fl ow rati o speci fi cati on, Mul ti Frac adjusts the fl ow rate of a
connecti ng stream or the duty of a heater.
If the adjusted variable is You enter the
A connecting stream flow Connecting stream number in the IC-Stream field
A heater duty Heater column and stage numbers
You can pl ace the cal cul ated heat duty i n an outl et heat stream usi ng the
I nl etsOutl ets form. I ni ti al esti mates for these adjusted vari abl es are not
requi red.
Be cauti ous when sel ecti ng the:
Associ ated stage wi th vari ed heat duty
Connecti ng stream wi th vari ed fl ow rate
Versi on 10
Chapter 4
Efficiencies
Vapori zati on
Murphree
Eff
y
K x
i
v i j
i j i j
,
, ,
Eff
y y
K x y
i j
M i j i j
i j i j i j
,
, ,
, , ,
+
+
1
1
Where:
Eff
v
Eff
M
j = Stage i ndex
stages on the Col umns Setup Confi gurati on sheet. Then use the Col umns
Effi ci enci es form to enter the effi ci enci es.
effi ci enci es can be qui te di fferent. Detai l s on usi ng and esti mati ng these
effi ci enci es are descri bed by Hol l and, Fundamentals of Multi-Component
Distillation, McGraw-Hi l l Book Company, 1981.
Versi on 10
Columns
Algorithms
Mul ti Frac has three convergence al gori thms. Use the Overal l fi el d on the
Convergence Methods sheet to sel ect the al gori thm. The defaul t standard
al gori thm i s appropri ate for most appl i cati ons. Your choi ce of al gori thm depends
on the types of systems you are model i ng:
Application Algorithm
Air separation Standard
Close-boiling, e.g., C3 splitter Standard
Wide-boiling, e.g., absorbers Sum-Rates
Petroleum refining, e.g., crude unit Sum-Rates
Ethylene plant primary fractionator Sum-Rates
Highly-nonideal, e.g., azeotropic Newton
Highly-coupled design specifications Sum-rates or Newton
Rating Mode
I n rati ng mode, Mul ti Frac cal cul ates col umn profi l es and product composi ti ons
based on speci fi ed val ues of col umn parameters. Exampl es of col umn parameters
are refl ux rati o, reboi l er duti es, and feed fl ow rates.
Design Mode
I n desi gn mode, use the Desi gnSpecs form to speci fy col umn performance
parameters (such as puri ty or recovery). You must i ndi cate whi ch vari abl es to
mani pul ate to achi eve these speci fi cati ons usi ng the Vary form. You can speci fy
any vari abl es that are al l owed i n rati ng mode, except:
Number of stages
Pressure profi l e
Effi ci enci es
Subcool ed refl ux temperature
Degrees of subcool i ng
Locati ons of feeds, products, heaters, and connecti ng streams
Versi on 10
Chapter 4
The fl ow rates of i nl et materi al streams and the duti es of i nl et heat streams can
al so be mani pul ated vari abl es.
Purity Stream, including an internal stream
Recovery of any component groups Set of product streams
Flow rate of any component groups Internal stream or set of product streams
Temperature Stage
Heat duty Stage or connecting stream
Heat duty ratio Stage or connecting stream to any other stage or connecting stream
Ratio or difference of any pair of properties in

a Prop-Set
Single or paired internal or product stream
Flow ratio of any component groups to any
First group can be in any internal streams
components, relative to any other group of components.
You can express recovery as a fraction of the same components in a subset of the feed stream.
See ASPEN PLUS User Gui de.
The second group can be in any other internal streams, or set of feed or product streams.
Column Convergence
Mul ti Frac uses the i nsi de-out approach for col umn convergence. You can choose
from two al gori thm vari ants of thi s approach:
Standard
Sum-rates
To sel ect an al gori thm, use the Overal l fi el d on the Convergence Methods sheet.
The standard al gori thm uses the standard i nsi de-out formul ati on for the i nsi de
l oop. I t uses ei ther the nested or si mul taneous approach (speci fi ed as the Mi ddl e
l oop method on the Convergence Methods sheet) to converge the desi gn
speci fi cati ons. Thi s al gori thm i s appropri ate for most systems.
The sum-rates al gori thm uses:
A sum-rates vari ant formul ati on for the i nsi de l oop
The si mul taneous approach to converge the desi gn speci fi cati ons
Versi on 10
Columns
Sum-rates i s wel l sui ted for:
Wi de-boi l i ng systems
Col umns wi th steep fl ow gradi ents
Mul ti Frac al so has the Newton al gori thm, whi ch uses a Napthal i -Sandhol m
formul ati on. I t sol ves the col umn-descri bi ng equati ons and desi gn speci fi cati ons
si mul taneousl y, usi ng Newtons method. Thi s method can enhance convergence
for hi ghl y-noni deal systems, such as azeotropi c di sti l l ati on. The Newton
al gori thm i s general l y sl ower than the other al gori thms.
Design Specification Convergence
Mul ti Frac provi des two methods for handl i ng desi gn speci fi cati on convergence:
Nested mi ddl e l oop
Si mul t mi ddl e l oop
When you use the nested mi ddl e l oop method, the al gori thm attempts to sati sfy
the desi gn speci fi cati ons by determi ni ng the val ues of the mani pul ated vari abl es
(wi thi n thei r bounds) that mi ni mi ze the wei ghted sum of squares functi on:

_
,
m
m
w
G G
G
^
**
2
Where:
m = Desi gn speci fi cati on number
$
G
G = Desi red val ue
G
**
= Scal i ng factor
w = Wei ghti ng factor
For puri ty and recovery,
$
G and G are transformed by taki ng the l ogari thm, and
G
**
i s taken as uni ty.
When you use the si mul t mi ddl e l oop method, the fol l owi ng al gori thm sol ves the
desi gn speci fi cati on functi ons si mul taneousl y wi th the col umn descri bi ng
equati ons:
( )
F G G G
m m m m

$
/
**
0
Versi on 10
Chapter 4
The wei ghti ng factor i s not avai l abl e for thi s method.
You can handl e desi gn speci fi cati on convergence by usi ng ei ther scal i ng factors or
wei ghti ng factors. The fol l owi ng al gori thm attempts to sati sfy desi gn
speci fi cati ons by determi ni ng the val ues of the mani pul ated vari abl es (wi thi n
thei r bounds) that mi ni mi ze the wei ghted sum of squares functi on:

_
,
m
m
w
G G
G
$
**
2
Where:
m = Desi gn speci fi cati on number
$
G
G = Desi red val ue
G
**
= Scal i ng factor
w = Wei ghti ng factor
Initialization
Use I ni ti al i zati on Method on the Convergence Methods sheet to choose the
i ni ti al i zati on method.
Mul ti Frac has two i ni ti al i zati on procedures:
Standard
Crude
Standard i s appropri ate for most systems. You must enter at l east the top and
bottom temperature esti mates for each col umn.
Crude i nvokes a speci al i ni ti al i zati on procedure desi gned for petrol eum refi ni ng
and ethyl ene pl ant pri mary fracti onator/quench tower appl i cati ons. Thi s
procedure i s desi gned for systems consi sti ng of a mai n col umn connected to any
number of si destri ppers. I f you speci fy the fol l owi ng i nformati on on the Col umns
Setup and/or Col umns Fl owSpecs forms, you do not need to provi de esti mates:
Al l stri pper bottoms fl ow rates
Ei ther the di sti l l ate or bottoms fl ow rate of the mai n col umn
Otherwi se, you must enter at l east the top and bottom temperature esti mates for
each col umn. You may enter profi l e esti mates on the Col umns Esti mates form to
enhance convergence. Temperature esti mates are usual l y adequate. Hi ghl y
noni deal systems may requi re composi ti on esti mates.
Versi on 10
Columns
Physical Properties
Use the Bl ockOpti ons form to overri de the gl obal physi cal property method. You
can speci fy a si ngl e property method on the Bl ockOpti ons form. Mul ti Frac uses thi s
property method for al l stages i n al l col umns.
Use the Col umns Properti es form to speci fy physi cal property methods when you
use a separate property method for an i ndi vi dual col umn. You can al so spl i t a
col umn i nto any number of segments, each usi ng a di fferent property methods.
Free Water Handling
Mul ti Frac can perform free-water cal cul ati ons. By defaul t, Mul ti Frac performs
free-water cal cul ati ons for the mai n col umn condenser. The free-water phase, i f
present, i s decanted.
Use the Col umns Properti es form to request free-water cal cul ati ons for
addi ti onal stages i n any col umn. You can defi ne addi ti onal water decant product
streams on the I nl etsOutl ets form. You can use thi s capabi l i ty to si mul ate the
pri mary fracti onator/quench tower combi nati on of an ethyl ene pl ant.
Solids Handling
Mul ti Frac handl es sol i ds by:
Temporari l y removi ng al l sol i ds from i nl et streams
Performi ng cal cul ati ons wi thout sol i ds
Adi abati cal l y mi xi ng sol i ds removed from i nl et streams wi th mai n col umn
l i qui d bottoms
Thi s cal cul ati on approach mai ntai ns an overal l mass and energy bal ance around
the Mul ti Frac bl ock. But the bottom stage l i qui d product wi l l not be i n exact
thermal or phase equi l i bri um wi th other bottom stage fl ows (for exampl e, the
bottom stage vapor fl ow).
Versi on 10
Chapter 4
Sizing and Rating of Trays and Packings
Mul ti Frac has extensi ve capabi l i ty to si ze, rate, and perform pressure drop
cal cul ati ons for trayed and packed col umns. Use the fol l owi ng forms to enter
speci fi cati ons:
TraySi zi ng
TrayRati ng
PackSi zi ng
PackRati ng
See Appendi x A for detai l s on tray and packi ng types and correl ati ons.
Versi on 10
Columns
PetroFrac
PetroFrac i s a ri gorous model desi gned for si mul ati ng al l types of compl ex vapor-
l i qui d fracti onati on operati ons i n the petrol eum refi ni ng i ndustry. Typi cal
operati ons i ncl ude:
Prefl ash tower
Atmospheri c crude uni t
Vacuum uni t
Catal yti c cracker mai n fracti onator
Del ayed coker mai n fracti onator
Vacuum l ube fracti onator
You al so can use PetroFrac to model the pri mary fracti onator/quench tower
combi nati on i n the quench secti on of an ethyl ene pl ant. PetroFrac can detect a
free-water phase i n the condenser or anywhere i n the col umn. I t can decant the
free-water phase on any stage. Al though PetroFrac assumes equi l i bri um stage
cal cul ati ons, you can speci fy ei ther Murphree or vapori zati on effi ci enci es. You
can use PetroFrac to si ze and rate col umns consi sti ng of trays and/or packi ngs.
PetroFrac can model both random and structured packi ngs.
Versi on 10
Chapter 4
Flowsheet Connectivity for PetroFrac
PetroFrac model s col umn confi gurati ons consi sti ng of a mai n col umn wi th any
number of pumparounds and si de stri ppers. You can speci fy a feed furnace. For
si ngl e col umns wi thout pumparounds and si de stri ppers, use RadFrac. For other
mul ti col umn systems such as ai r separati on systems, Petl yuk towers, and
compl ex pri mary fracti onators, use Mul ti Frac.
Material Streams
One steam feed per stri pper (opti onal )
Outlet One vapor or l i qui d di sti l l ate, or both
One free water di sti l l ate stream (opti onal )
One bottoms product from the mai n col umn
Any number of si de products from mai n col umn (opti onal )
Any number of water decant products from mai n col umn (opti onal )
One bottoms product per si de stri pper
Any number of pseudoproduct streams (opti onal )
Versi on 10
Columns
You can use any number of pseudoproduct streams to represent:
Col umn i nternal streams
Pumparound streams
Col umn connecti ng streams
A pseudoproduct stream does not affect col umn resul ts.
Heat Streams
Inlet One heat stream per stage for the mai n col umn (opti onal )
One heat stream per pumparound heater/cool er (opti onal )
One heat stream per stri pper reboi l er (opti onal )
One heat stream per stri pper bottom l i qui d return (opti onal )
Outlet One heat stream per stage for the mai n col umn (opti onal )
One heat stream per pumparound heaters/cool er (opti onal )
One heat stream per stri pper reboi l er (opti onal )
One heat stream per stri pper bottom l i qui d return (opti onal )
PetroFrac uses an i nl et heat stream as a duty speci fi cati on for al l stages except
the condenser, reboi l er, pumparounds, and stri pper bottom l i qui d return.
I f you do not gi ve suffi ci ent operati ng col umn speci fi cati ons on the Setup
Confi gurati on sheet, PetroFrac uses a heat stream as a speci fi cati on for the
condenser and reboi l er.
I f you do not gi ve two speci fi cati ons on the Pumparounds Speci fi cati ons sheet,
PetroFrac uses a heat stream as a speci fi cati on for pumparounds.
I f you do not gi ve two speci fi cati ons for the bottom l i qui d return on the Stri ppers
Setup Li qui dReturn sheet, PetroFrac uses a heat stream as a speci fi cati on.
I f you gi ve two speci fi cati ons on the Setup Confi gurati on sheet or Pumparounds
Speci fi cati ons sheet, PetroFrac does not use the i nl et heat stream as a
speci fi cati on. The heat stream suppl i es the requi red heati ng or cool i ng.
Use opti onal outl et streams for the net heat duty of the condenser, reboi l er, and
pumparounds. The val ue of the outl et heat stream equal s the val ue of the i nl et
heat stream (i f any) mi nus the actual (cal cul ated) heat duty.
Main Column
The mai n col umn can have any number of i nl et streams. I t can al so have up to
three product streams per stage (one vapor, one hydrocarbon l i qui d, and one free
water).
Versi on 10
Chapter 4
Side Strippers
The si de stri ppers can have a steam feed. They must have a l i qui d bottoms
product. You can use a heat stream as the heat source for the reboi l er. I f you do not
speci fy the reboi l er duty, bottoms fl ow rate, and steam feed, PetroFrac uses the
heat stream as a duty speci fi cati on.
Opti onal l y, the stri pper l i qui d bottoms may be parti al l y returned to the mai n
col umn. To speci fy a bottom l i qui d return, you must enter two speci fi cati ons on
the Stri ppers Setup Li qui dReturn sheet.
Feed Furnace
You can speci fy a feed furnace. A feed furnace can have any number of feeds. The
vapor and l i qui d streams from the furnace are fed to the stage where the furnace i s
attached.
Specifying PetroFrac
Wi thi n each col umn or stri pper, stages are numbered from the top down. I f
present, the mai n col umn condenser i s stage 1.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts of PetroFrac:
Pumparounds Specify pumparound specifications and view results
Pumparounds Hcurves Specify pumparound heating or cooling curve tables and view tabular results
Strippers Setup Specify stripper operating specifications
Strippers Efficiencies Specify stripper column or stage efficiencies
Strippers ReboilerHcurves Specify stripper reboiler heating or cooling curve tables and view tabular results
Strippers TraySizing Specify sizing calculation parameters for tray stripper sections, and view results
Strippers TrayRating Specify rating calculation parameters for tray stripper sections, and view results
Strippers PackSizing Specify sizing calculation parameters for packed stripper sections, and view results
Strippers PackRating Specify rating calculation parameters for packed stripper sections, and view results
Strippers Properties Specify physical property parameters for stripper sections
continued
Versi on 10
Columns
Strippers Estimates Specify estimates for stripper temperatures and flows
Strippers Results View stripper product stream and connecting stream results
Strippers Profiles View stripper profiles
HeatersCoolers Specify stage heating or cooling specifications
RunbackSpecs Specify runback specification parameters
Efficiencies Specify stage or component efficiencies
DesignSpecs Specify design specifications, manipulated variables, and view results
TraySizing Specify sizing calculation parameters for tray column sections, and view results
TrayRating Specify rating calculation parameters for tray column sections, and view results
PackSizing Specify sizing calculation parameters for packed column sections, and view results
PackRating Specify rating calculation parameters for packed column sections, and view results
Properties Specify physical property parameters for column sections
Estimates Specify estimates for column temperatures and flows
Convergence Specify convergence parameters
Report Specify block-specific report options and pseudostreams
UserSubroutines Specify user subroutines for tray and packing rating and sizing
Connectivity View stream connectivity for the PetroFrac block
ResultsSummary View key column results for the overall PetroFrac column
Profiles View column profiles
Versi on 10
Chapter 4
Main Column
You defi ne the mai n col umn confi gurati on usi ng Condenser and Reboi l er on the
Setup Confi gurati on sheet. PetroFrac al l ows si x condenser types:
Subcool ed
Total
Parti al wi th vapor di sti l l ate product onl y
Parti al wi th both vapor and l i qui d di sti l l ate products
No condenser, wi th pumparound to top stage
No condenser, wi th external feed to top stage
You can speci fy one of three reboi l er types:
Kettl e reboi l er
No reboi l er, wi th pumparound to bottom stage
No reboi l er, wi th external feed to bottom stage
The types and number of requi red operati ng speci fi cati ons depend on the col umn
confi gurati on. Normal l y, you must enter two col umn operati ng speci fi cati ons. I f
ei ther a condenser or a reboi l er i s absent, you must enter one speci fi cati on. I f
both the condenser and reboi l er are absent, do not enter any speci fi cati on.
Feed Stream Handling
Use the Setup Streams sheet to speci fy the feed and product stage l ocati ons. You
may al so i denti fy a feed as the stri ppi ng steam, and overri de i ts fl ow by speci fyi ng
a steam-to-product rati o.
PetroFrac provi des three conventi ons for handl i ng feed streams (see PetroFrac
Feed Conventi on Above-Stage and PetroFrac Feed Conventi on On-Stage i n the
fol l owi ng fi gures):
Above-Stage
On-Stage
Furnace
When Feed-Conventi on i s Above-Stage, PetroFrac i ntroduces a materi al stream
between adjacent stages. The l i qui d porti on fl ows to the stage (n) you speci fy. The
vapor porti on fl ows to the stage above (n 1). You can i ntroduce a l i qui d feed to
the top stage (or condenser) by speci fyi ng Stage=1. You can i ntroduce a vapor
feed to the bottom stage (or reboi l er) by speci fyi ng Stage=Number of stages+1.
When Feed-Conventi on i s On-Stage, both the l i qui d and vapor porti ons of a feed
fl ow to the stage (n) you speci fy.
Versi on 10
Columns
Vapor
Liquid
n - 1
Mixed feed
to stage n
PetroFrac Feed Convention Above-Stage
n - 1
n + 1
n
Mixed feed
to stage n
PetroFrac Feed Convention On-Stage
When Feed-Conventi on i s Furnace, a furnace i s attached to the stage (n) you
speci fy. The feed enters the furnace before bei ng i ntroduced to the speci fi ed
stage.
Feed Furnace
PetroFrac can si mul ate a feed furnace si mul taneousl y wi th the col umn/stri ppers.
You can si mul ate the feed furnace as a si mpl e heater or as a si ngl e stage fl ash wi th
or wi thout feed overfl ash bypass to the furnace. You can speci fy one of the
fol l owi ng:
Heat Duty
Temperature
Fracti onal overfl ash
Versi on 10
Chapter 4
To do this Use this sheet
Define a feed to the feed furnace Setup Streams (Feed Convention)
Enter a furnace model type and associated specifications Setup Furnace
You can sel ect from three furnace model types, as shown i n the next three
fi gures.
Heat
Feed
Main Column
Furnace Modeled as a Stage Heat Duty
Feed Furnace
Main Column
Furnace Modeled as a Single Stage Flash
Versi on 10
Columns
Feed
Furnace
Main Column
Furnace Modeled as a Single Stage Flash with Overflash Bypass
If Model= PetroFrac models the furnace as And calculates
Heater Stage heat duty on the feed stage
Flash Single-stage flash Furnace temperature, degree of vaporization,
vapor/liquid compositions
Flash-Bypass Single-stage flash with the overflash bypassed
back to the furnace
Furnace temperature, degree of vaporization,
vapor/liquid compositions
Liquid Runbacks
Use the RunbackSpecs form to speci fy the fl ow rate of l i qui d runback from any
stage. When you enter a l i qui d runback speci fi cati on, you must al l ow PetroFrac to
adjust one of the fol l owi ng:
Fl ow rate of a pumparound
Duty of an i nterstage heater/cool er
Pumparounds
Use the fol l owi ng sheets to enter speci fi cati ons for pumparounds.
Use this sheet To enter
Pumparounds
Specifications
Pumparound connectivity and cooler/heater specifications
Report PseudoStreams Pseudostream assignment for the pumparound
Hcurves Specifications Heating/cooling curve specifications
Versi on 10
Chapter 4
Pumparounds are associ ated wi th the mai ncol umn. They can be total or parti al
drawoffs of the stage l i qui d fl ow. You must speci fy the draw and return stage
l ocati ons for each pumparound. For parti al drawoffs, you must speci fy two of the
fol l owi ng:
Fl ow rate
Temperature
Temperature change
Heat Duty
For total drawoffs, you must speci fy one of the fol l owi ng:
Temperature
Temperature change
Heat Duty
Side Strippers
Use the Stri pper forms and sheets to enter speci fi cati ons for si de stri ppers.
Si de stri ppers may be ei ther steam-stri pped or reboi l ed. For steam stri ppers, you
must enter a steam stream. You can overri de i ts fl ow rate by speci fyi ng a steam-
to-product rati o. For reboi l ed stri ppers, you must speci fy a reboi l er duty.
PetroFrac assumes:
A l i qui d draw goes from the mai n col umn to the top of the stri pper.
The stri pper overhead i s returned to the mai n col umn.
You must speci fy the draw and return stage l ocati ons. You can al so:
Return a fracti on of the stri pper bottoms to the mai n col umn
Speci fy addi ti onal l i qui d draws from other stages of the mai n col umn as feeds
to the stri ppers
Efficiencies
Vapori zati on
Murphree
Eff
y
K x
i
v i j
i j i j
,
, ,
Eff
y y
k x y
i j
M i j i j
i j i j i j
,
, ,
, , ,
+
+
1
1
Versi on 10
Columns
Where:
Eff
v
Eff
M
j = Stage i ndex
stages on the Setup Confi gurati on sheet and Stri ppers Setup Confi gurati on sheet
as Number of stages. Then use the Effi ci enci es and Stri ppers Effi ci enci es forms
to enter the effi ci enci es.
effi ci enci es can be qui te di fferent. Detai l s on usi ng and esti mati ng these
effi ci enci es are descri bed by Hol l and, Fundamentals of Multi-Component
Distillation, McGraw-Hi l l Book Company, 1981.
Convergence
For convergence PetroFrac uses:
The sum-rates vari ant of the i nsi de-out al gori thm
A speci al i ni ti al i zati on procedure desi gned for petrol eum refi ni ng appl i cati ons
PetroFrac general l y does not need i ni ti al esti mates. For ethyl ene pl ant pri mary
fracti onator/quench tower combi nati ons, you shoul d provi de temperature
esti mates.
To enhance convergence, you may enter profi l e esti mates on the fol l owi ng
PetroFrac forms:
Esti mates
Stri ppers Esti mates
Temperature esti mates are usual l y adequate. You can i ncrease convergence
stabi l i ty by sel ecti ng varyi ng degrees of dampi ng on the Convergence Basi c sheet.
Versi on 10
Chapter 4
Rating Mode
I n rati ng mode, PetroFrac cal cul ates the col umn profi l es and product composi ti ons
based on speci fi ed val ues of col umn parameters. Exampl es of col umn parameters
are:
Refl ux rati o
Reboi l er duti es
Feed fl ow rates
Furnace temperature
Pumparound l oads
Design Mode
I n desi gn mode you can mani pul ate subsets of the col umn parameters to achi eve
certai n speci fi cati ons on col umn performance.
Purity Stream, including internal streams
Recovery of any components group Set of product streams
Flow rate of any components group Internal stream or set of product streams
Flow rates of any components groups to any
Internal streams to any other internal streams, or set of feed or product
streams
Temperature Stage
Heat duty Stage
Fractional overflash Stage
TBP and D86 temperature gaps Pair of product streams
TBP temperature Product stream
D86 temperature Product stream
D1160 temperature Product stream
Vacuum distillation temperature Product stream
API gravity Product stream
Standard liquid density Product stream
Specific gravity Product stream
Flash point Product stream
Pour point Product stream
Refractive index Product stream
continued
Versi on 10
Columns
Reid vapor pressure Product stream
Difference of any pair of Prop-Set properties Pair of product streams

Watson UOP K factor Product stream
Express the purity as the sum of mole, mass, or standard liquid volume fraction of any group of
components relative to any other group of components.
Express recovery as a fraction of the same components in a subset of feed streams.
See ASPEN PLUS User Gui de, Chapter 28.

You can al so speci fy overfl ash for a furnace feed stream.
Physical Properties
Use the Bl ockOpti ons form to overri de the gl obal physi cal property method. You
can speci fy one method on thi s form, whi ch PetroFrac uses for al l stages i n the
mai n col umn and stri ppers.
You can al so spl i t the mai n col umn or a stri pper i nto any number of segments,
each usi ng a di fferent property method.
Use this sheet When you use different properties for
Properties Property Sections The main column
Strippers Properties Property Sections A stripper
Free Water Handling
PetroFrac can perform free-water cal cul ati ons i n the mai n col umn and si de
stri ppers. By defaul t, PetroFrac performs free-water cal cul ati ons for the mai n
col umn condenser. The free-water phase, i f present, i s decanted.
To do this Use these sheets
Request free-water calculations for additional stages in the
main columns and strippers
Properties Freewater Stages
Strippers Properties Freewater Stages
Define additional water decant product streams for the main
column
Setup Streams
Versi on 10
Chapter 4
Solids Handling
PetroFrac handl es sol i ds by:
Temporari l y removi ng al l sol i ds from i nl et streams
Performi ng cal cul ati ons wi thout sol i ds
Adi abati cal l y mi xi ng sol i ds removed from i nl et streams wi th mai n col umn
l i qui d bottoms
Thi s cal cul ati on approach mai ntai ns an overal l mass and energy bal ance around
the PetroFrac bl ock. But the bottom stage l i qui d product wi l l not be i n exact
thermal or phase equi l i bri um wi th other bottom stage fl ows (for exampl e, the
bottom stage vapor fl ow).
Sizing and Rating of Trays and Packings
PetroFrac has extensi ve capabi l i ti es to si ze, rate, and perform pressure drop
cal cul ati ons for trayed and packed col umns. Use the fol l owi ng PetroFrac forms to
enter speci fi cati ons:
TraySi zi ng, TrayRati ng, PackSi zi ng, PackRati ng
Stri ppers TraySi zi ng, Stri ppers TrayRati ng, Stri ppers PackSi zi ng, Stri ppers
PackRati ng
See Appendi x A for detai l s on tray and packi ng types and correl ati ons.
Versi on 10
Columns
RateFrac
Rate-Based Distillation
RateFrac i s a rate-based nonequi l i bri um model for si mul ati ng al l types of
mul ti stage vapor-l i qui d fracti onati on operati ons. RateFrac si mul ates actual tray
and packed col umns, rather than the i deal i zed representati on of equi l i bri um
stages. RateFrac expl i ci tl y accounts for the underl yi ng i nterphase mass and heat
transfer processes to determi ne the degree of separati on. RateFrac does not use
empi ri cal factors such as effi ci enci es and the Hei ght Equi val ent to a Theoreti cal
Pl ate (HETP).
RateFrac i s appl i cabl e for:
Ordi nary di sti l l ati on
Absorpti on
Reboi l ed absorpti on
Stri ppi ng
Reboi l ed stri ppi ng
Extracti ve and azeotropi c di sti l l ati on
RateFrac i s sui tabl e for:
Two-phase systems
Narrow and wi de-boi l i ng systems
Systems exhi bi ti ng strong l i qui d phase noni deal i ty
RateFrac can al so detect and handl e a free water phase i n the condenser.
RateFrac can model col umns wi th chemi cal reacti ons. Reacti ons i ncl ude:
Equi l i bri um
Rate-control l ed
El ectrol yti c
RateFrac model s a compl ex confi gurati on consi sti ng of a si ngl e col umn or
i nterl i nked col umns. The confi gurati on may have:
Any number of col umns, each wi th any number of RateFrac Segments
Any number of connecti ons between col umns or wi thi n each col umn
Arbi trary fl ow spl i tti ng and mi xi ng of connecti ng streams
RateFrac can handl e operati ons wi th:
Si de stri ppers
Pumparounds
Bypasses
External heat exchangers
RateFrac can be used to
Rate exi sti ng col umns
Desi gn new col umns
Versi on 10
Chapter 4
You can defi ne pseudoproduct streams to represent col umn i nternal fl ows or
connecti ng streams i n RateFrac.
You can use Fortran Bl ocks, Sensi ti vi ty Anal ysi s, and Case Study bl ocks to vary
confi gurati on parameters, such as feed l ocati on or number of segments.
RateFrac can produce segmentwi se col umn profi l e pl ots.
RateFrac can be used wi th other ASPEN PLUS features and capabi l i ti es much i n
the same way as the equi l i bri um-based model s, RadFrac, PetroFrac, and
Mul ti Frac.
Flowsheet Connectivity for RateFrac
1
Vapor Distillate or
Interconnecting Stream
Heat (optional)
Heat (optional)
Heat (optional)
Heat (optional)
Side Products
(Heater optional)
Bottoms or
(Heater optional)
Reflux
N
Bottom Segment
or Reboiler Heat
Duty (optional)
Top Segment or
Condenser Heat
Duty (optional)
Feeds
Pumparounds
and Bypasses
(Heater optional)
RateFrac model s si ngl e and i nterl i nked col umns. Any number of col umns can be
connected by any number of connecti ng streams. Each connecti ng stream can
have an associ ated heater.
Each col umn may have:
Any combi nati on of packed and tray segments
Any number of connecti ng streams
Any number of si de product streams
Versi on 10
Columns
Material Streams
Outlet Up to two product streams (one vapor, one l i qui d) per segment
One water di sti l l ate product stream (opti onal )
Each col umn must have:
At l east one vapor or l i qui d stream l eavi ng the top segment
One l i qui d stream l eavi ng the bottom segment
When you model i nterl i nked col umns, the top and bottom streams can be
connecti ng streams. However, the free-water stream from the condenser cannot
be a connecti ng stream.
Heat Streams
Inlet One heat stream per segment (opti onal )
One heat stream per connecti ng stream (opti onal )
Outlet One heat stream per connecti ng stream (opti onal )
RateFrac uses an i nl et heat stream as a duty speci fi cati on for al l segments except
the condenser, reboi l er, and connecti ng streams. I f you do not provi de two col umn
operati ng speci fi cati ons on the Col umns Setup Confi gurati on sheet, RateFrac uses
a heat stream as a speci fi cati on for the condenser and reboi l er.
I f you do not provi de two speci fi cati ons on the ConnectStreams I nput sheet,
RateFrac uses a heat stream as a speci fi cati on for connecti ng streams.
I f you provi de two speci fi cati ons on the Col umns Setup Confi gurati on sheet or
ConnectStreams I nput sheet, RateFrac does not use the i nl et heat stream as a
You can use opti onal outl et heat streams for the net heat duty of the condenser,
reboi l er, and connecti ng streams. The val ue of the outl et heat stream equal s the
val ue of the i nl et heat stream (i f any), mi nus the actual (cal cul ated) heat duty.
Versi on 10
Chapter 4
The Rate-Based Modeling Concept
Most model s avai l abl e for si mul ati ng and desi gni ng mul ti component, mul ti stage
separati on processes are based on the i deal i zed concept of equi l i bri um or
theoreti cal stages. Thi s approach assumes that the l i qui d and vapor phases
l eavi ng any stage are i n thermodynami c equi l i bri um wi th each other. The phase
composi ti ons, temperature, and vapor and l i qui d fl ow profi l es are cal cul ated by
sol vi ng the governi ng materi al bal ances, energy bal ances, and equi l i bri um
rel ati ons for each stage.
I n practi ce, col umns rarel y operate under thermodynami c equi l i bri um condi ti ons.
Vapor-l i qui d equi l i bri um prevai l s onl y at the i nterface separati ng vapor and
l i qui d phases. The separati on achi eved i n a mul ti stage col umn depends on the
i nterphase mass and heat transfer rate processes. Mul ti component mass transfer
i nteracti ons can al so have pronounced effects on the separati on.
When the equi l i bri um approach i s used to model a tray col umn, a correcti on
factor (referred to as an effi ci ency) attempts to account for the departure from
equi l i bri um. Many defi ni ti ons for effi ci ency exi st, wi th wi de vari ati ons i n
compl exi ty and accuracy. I n general , effi ci enci es depend on:
Physi cal characteri sti cs of the equi pment, such as col umn confi gurati on
Hydrodynami cs of the col umn
Fl ui d properti es of the system
Murphree vapor effi ci enci es are the most wi del y used. These effi ci enci es
general l y vary from stage to stage wi thi n a col umn, and from component to
component. For mul ti component systems, there are no theoreti cal l i mi tati ons on
Murphree effi ci enci es. Experi mental evi dence shows that component effi ci enci es:
May vary strongl y from component to component
Can take any val ue i ncl udi ng negati ve val ues
Methods used to cal cul ate component effi ci enci es general l y do not i ncl ude the
effect of the departure from thermal equi l i bri um.
Packed col umns are al so desi gned usi ng the equi l i bri um stage concept. However,
HETP i s commonl y used i n pl ace of effi ci enci es. HETP vari es wi th:
Type and si ze of the packi ng
Hydrodynami cs of the col umn
Fl ui d properti es of the system
Li ke effi ci enci es, HETPs may vary strongl y from poi nt to poi nt wi thi n a col umn
and from system to system.
Versi on 10
Columns
RateFrac i s based on a fundamental and ri gorous approach. Thi s approach avoi ds
uncertai nti es that resul t when the equi l i bri um approach i s used wi th esti mated
effi ci enci es or HETP. RateFrac di rectl y i ncl udes mass and heat transfer rate
processes i n the system of equati ons representi ng the operati on of separati on
process uni ts. RateFrac:
Descri bes the si mul taneous mass and heat transfer rate phenomena
Accounts for the mul ti component i nteracti ons between si mul taneousl y
di ffusi ng speci es
For nonreacti ve systems, RateFrac compri ses:
Mass and heat bal ances around vapor and l i qui d phases
Mass and heat transfer rate model s to determi ne i nterphase transfer rates
Vapor-l i qui d equi l i bri um rel ati ons appl i ed at i nterfaci al condi ti ons
Correl ati ons to esti mate mass and heat transfer coeffi ci ents and i nterfaci al
areas
For chemi cal l y reacti ve systems, RateFrac i ncl udes equati ons to account for the
i nfl uence of chemi cal reacti ons on heat and mass transfer rate processes. For
systems i nvol vi ng equi l i bri um reacti ons, RateFrac i ncl udes equati ons to
represent the chemi cal equi l i bri um condi ti ons.
RateFrac compl etel y avoi ds the need for effi ci enci es i n tray col umns or HETPs i n
packed col umns. RateFrac has far greater predi cti ve capabi l i ti es than the
conventi onal equi l i bri um model .
Specifying RateFrac
RateFrac numbers segments from the top down, starti ng wi th the condenser (or
starti ng wi th the top segment i f there i s no condenser).
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RateFrac:
BlockParameters Specify overall block parameters, convergence and initialization parameters, block-
specific diagnostic message levels, and feed flash convergence parameters
Columns Setup Specify basic column configuration and operating conditions
Columns TraySpecs Specify tray column section parameters
Columns PackSpecs Specify packed column section parameters
Columns Reactions Assign reactions to column sections, and specify vapor and liquid holdup data
continued
Versi on 10
Chapter 4
Columns Estimates Specify initial estimates for segment temperatures, and vapor and liquid flows and
compositions
Columns
EquilibriumSegments
Specify optional equilibrium segments and column efficiencies
Columns HeatersCoolers Specify segment heating or cooling and utility exchangers
Columns FlowTempSpecs Specify liquid, vapor, and temperature specifications
Columns Results View column performance summary
Columns Profiles View column profiles
Columns InterfaceProfiles View column interface profiles
Columns EfficienciesFlooding View tray and component efficiencies, packing HETPs, and flooding summary
Columns TransferCoefficients View binary diffusion, binary mass, and heat transfer coefficients
InletsOutlets Specify feed and product stream locations and conventions, inlet and outlet heat
streams
ConnectStreams Specify connecting stream sources and destinations and view results
DesignSpecs Specify design specifications and view convergence results
FlowRatios Specify the flow ratio and view results
ConnectStreamHcurves Specify connecting stream heating or cooling curve tables and view tabular results
Reports Specify block-specific report options, and pseudostream information
UserSubroutines Specify user subroutine parameters for mass and heat transfer coefficients, interfacial
area, pressure drop, and kinetics
ResultsSummary View material and energy balance results and overall split fractions
Column Numbering
I ndi vi dual col umns are i denti fi ed by a col umn number. The numberi ng order does
not affect al gori thm performance. Wi thi n each col umn, segments are numbered
from top to bottom, starti ng wi th the condenser (when present).
Versi on 10
Columns
Stream Definition
RateFrac uses four types of streams:
External streams
Connecti ng streams
I nternal streams
Pseudostreams
External streams are the standard RateFrac i nl et and outl et streams. They are
i denti fi ed by stream I Ds.
Connecti ng streams are streams wi thi n RateFrac but external to i ndi vi dual
col umns. These streams are i denti fi ed by connecti ng stream numbers.
Connecti ng streams may connect two col umns or segments of the same col umn
(such as bypasses and pumparounds). You can associ ate a heater wi th any
connecti ng stream. Heaters are i denti fi ed by the connecti ng stream number.
I nternal streams are the l i qui d or vapor fl ows between adjacent segments of the
same col umn. These streams are i denti fi ed by a segment number and a col umn
number.
Pseudostreams store the resul ts of i nternal and connecti ng streams. They are a
subset of external outl et streams. Unl i ke normal outl et streams, pseudostreams
do not parti ci pate i n the bl ock materi al bal ance cal cul ati ons.
Material Feed Streams
RateFrac uses two conventi ons for handl i ng materi al feed streams (see RateFrac
Feed Conventi ons i n the fol l owi ng fi gures):
Above segment
On segment
Segment n-1
Mixed Feed to
Segment n
Segment n
Vapor
Liquid
RateFrac Feed Convention Above Segment
Versi on 10
Chapter 4
Segment n-1
Mixed Feed to
Segment n
Segment n
Segment n + 1
Vapor
Liquid
RateFrac Feed Convention On Segment
When the feed conventi on i s defi ned as Above segment, RateFrac i ntroduces a
materi al stream between adjacent segments. The l i qui d porti on fl ows to segment
n, speci fi ed as the feed segment. The vapor porti on fl ows to the segment above
(segment n-1 i n the fi gure RateFrac Feed Conventi on Above segment). You can
i ntroduce a l i qui d to the top segment (or condenser) by speci fyi ng Segment=1.
You can i ntroduce a vapor feed to the bottom segment (or reboi l er), by speci fyi ng
the segment equal to the l ast segment i n the col umn +1. When a two-phase feed
stream i s fed to segment 1, the vapor phase i s combi ned di rectl y wi th the vapor
di sti l l ate. Si mi l arl y, when a two-phase feed stream i s fed to the l ast segment of
that col umn + 1, the l i qui d phase i s combi ned di rectl y wi th the l i qui d bottoms
product.
When the feed conventi on i s defi ned as On segment, both the l i qui d and vapor
porti ons of the feed fl ow to segment speci fi ed (segment n i n the previ ous fi gure
RateFrac Feed Conventi on On segment).
RateFrac assumes that a vapor feed (or the vapor porti on of a mi xed feed)
combi nes wi th the vapor phase i n the segment i t enters. RateFrac al so assumes
that a l i qui d feed (or the l i qui d porti on of a mi xed feed) combi nes wi th the l i qui d
phase i n the segment i t enters.
Versi on 10
Columns
Column Configuration
Speci fy the col umn confi gurati on by i ndi cati ng the fol l owi ng on the Col umns
Confi gurati on sheet:
Number of segments
Presence or absence of condensers and reboi l ers
Equi l i bri um and nonequi l i bri um segments
Connecting Streams
RateFrac al l ows any number of connecti ng streams. Any number of these streams
can have the same:
Source col umn, segment, and phase
Desti nati on col umn and segment
RateFrac i ntroduces connecti ng streams on the desti nati on segment regardl ess of
thei r phase (Conventi on = On Segment). Al l connecti ng streams can have a
heater. Enter al l speci fi cati ons for connecti ng streams on the ConnectStreams
I nput sheet. RateFrac does not al l ow phase change for connecti ng streams.
Connecti ng streams can be ei ther a total or a parti al drawoff of the segment fl ow.
Enter the requi red speci fi cati ons as fol l ows:
If the drawoff type is You enter
Partial Two of the following: flow, temperature or temperature change and heat duty
Total One of the following: temperature or temperature change and heat duty
Enter zero for heat duty if heater is absent.
Flow is taken as the net flow of the segment, excluding any product flow and any other connecting
stream flow.
Required Specifications
You must speci fy the total number of col umns and connecti ng streams.
Use this form To enter Such as
Columns TraySpecs Tray specifications Number of trays or
Number of trays per segment
Tray type
Tray characteristics
Columns PackSpecs Packing specifications Total height of packing or
Height of packing per segment
Packing type
Packing characteristics
Versi on 10
Chapter 4
You must al so speci fy:
I nl et stream l ocati ons
Heat stream l ocati ons, heat duty, and phase
Pressure profi l e for each col umn
Condenser type
Two operati ng speci fi cati ons for mul ti segment col umns and one for si ngl e-
segment col umns
Source and desti nati on of any connecti ng stream and associ ated heater
speci fi cati ons
Outl et stream l ocati ons and phases. I f the outl et stream i s a si de drawoff
stream from a segment, you must speci fy i ts fl ow.
A segment refers to one of the fol l owi ng:
A sl i ce (or porti on) of packi ng i n a packed col umn (see the precedi ng fi gure,
Nonequi l i bri um Segment i n a Packed Col umn)
One (or more) tray(s) i n a tray col umn (see the precedi ng fi gure,
Nonequi l i bri um Segment i n a Tray Col umn)
A col umn consi sts of segments. To eval uate mass and heat transfer rates
between contacti ng phases, RateFrac uses one of the fol l owi ng:
Hei ght of packi ng i n a packed segment
Number of trays i n a tray segment
Nonequilibrium Segment in a Packed Column
Versi on 10
Columns
Nonequilibrium Segment in a Tray Column
Equilibrium Stages
RateFrac can model both equi l i bri um stages and nonequi l i bri um segments i n the
same col umn. Use the Col umns Equi l i bri umSegments form to speci fy the l ocati on
of equi l i bri um stages. When al l stages are equi l i bri um, you can obtai n the same
resul ts usi ng RateFrac as you can usi ng RadFrac, Mul ti Frac, or PetroFrac wi th
i deal stages.
Reactive Systems
RateFrac can handl e ki neti cal l y control l ed reacti ons and equi l i bri um reacti ons i n
both l i qui d and vapor phases. Chemi cal reacti ons can be of any type, i ncl udi ng:
Si mul taneous
Consecuti ve
Paral l el
Forward
Reverse
For ki neti cal l y control l ed reacti ons, the ki neti cs can be defi ned by one of the
fol l owi ng:
Bui l t-i n power l aw expressi ons
User-suppl i ed Fortran subrouti nes
Versi on 10
Chapter 4
For equi l i bri um reacti ons, the chemi cal reacti on equi l i bri um constant can be
defi ned ei ther i n terms of user-suppl i ed coeffi ci ents for a temperature-dependent
pol ynomi al , or can be computed from the reference state free energi es of
parti ci pati ng components.
RateFrac can model el ectrol yte systems usi ng both the apparent and the true
component approaches.
Enter the fol l owi ng i nformati on on the Reacti ons form:
Reacti on stoi chi ometry
Reacti on type
Phase i n whi ch reacti ons occur
Dependi ng on the reacti on type, you must enter ei ther the equi l i bri um constant
or ki neti c parameters. For el ectrol yti c reacti ons, you can al so enter the reacti on
data on the Chemi stry form.
To associ ate reacti ons wi th a col umn segment, enter the correspondi ng Reacti ons
I D (or Chemi stry I D or User Reacti ons I D) on the Col umns Reacti ons
Speci fi cati ons sheet.
For rate-control l ed reacti ons, you must enter hol dup data for the phase where
reacti ons occur.
For these segments Use this form to enter holdup information
Equilibrium Columns Reactions
Tray Columns TraySpecs
Packed Columns PackSpecs
Heaters and Coolers
Use the Col umns HeatersCool ers Si de Duti es sheet to speci fy:
Heat duty for a segment
Heater segment l ocati on (col umn and segment)
Phase
Use the Col umns HeatersCool ers Uti l i ty Exchangers sheet to speci fy cool i ng (or
heati ng) of any segment usi ng a cool ant (or heati ng fl ui d).
You can use a heat stream to provi de heat i ntegrati on. Heat i ntegrati on occurs
when the duty recovered from another bl ock i s used as the heat source of heaters
and cool ers. Enter heat stream data on the I nl etsOutl ets Heat Streams sheet.
Versi on 10
Columns
Physical Property Specifications
Use the RateFrac Bl ockOpti ons form to overri de the gl obal physi cal property
property method. You can speci fy onl y one property method on the Bl ockOpti ons
form. RateFrac uses thi s property method for the whol e col umn. RateFrac does not
al l ow mul ti pl e physi cal property methods.
Handling Free Water
RateFrac can perform free-water cal cul ati ons onl y i n condensers.
Rating Mode
I n rati ng mode, RateFrac cal cul ates temperatures, fl ows, and mol e fracti on profi l es
based on speci fi ed val ues of col umn parameters such as:
Refl ux rati o
Product fl ows
Heat duti es
Design Mode
I n desi gn mode, use the Desi gnSpecs form to speci fy col umn performance
parameters (such as puri ty or recovery). You must i ndi cate whi ch vari abl es to
mani pul ate to achi eve these speci fi cati ons usi ng the Vary form. You can speci fy
any vari abl es that are al l owed i n rati ng mode, except:
Number of col umns, segments, and connecti ng streams
Pressure profi l e
Locati ons of feeds, products, heaters, and connecti ng streams
Col umn confi gurati ons, i ncl udi ng the number of trays, tray characteri sti cs,
hei ght of packi ng, packi ng speci fi cati ons
Versi on 10
Chapter 4
The fl ows of i nl et materi al streams and the duti es of i nl et heat streams can al so
be mani pul ated vari abl es.
Purity Stream, including an internal stream
Recovery of any component groups Set of product streams
Flow of any component groups Internal stream or set of product streams

Component ratio Internal stream and a second internal stream or feed streams and product streams
Temperature of vapor stream Segment
Temperature of liquid stream Segment
Heat duty Condenser, reboiler, or a connecting stream
Ratio or difference of any pair of

properties in a Prop-Set
Single or paired internal or product stream
components, relative to any other group of components.
You can express recovery as a fraction of the same components in a subset of the feed stream.
See ASPEN PLUS User Gui de, Chapter 28.

Calculating Efficiency and HETP
From converged vapor and l i qui d composi ti on profi l es, RateFrac back-cal cul ates
the component Murphree vapor effi ci enci es. These effi ci enci es are defi ned for each
component as the fracti onal approach to equi l i bri um of the vapor stream l eavi ng
any segment, wi th the l i qui d stream l eavi ng the same segment.
Eff
y y
K x Y
ij
ij ij
ij ij ij
+
+
1
1
Where:
Eff = Murphree vapor effi ci ency
K = Vapor-l i qui d equi l i bri um K val ue
j = Segment i ndex
Versi on 10
Columns
For each segment of packed col umns, RateFrac cal cul ates the fracti onal approach
to equi l i bri um usi ng the same defi ni ti on as used for Murphree vapor effi ci ency.
RateFrac reports the hei ght of packi ng requi red to achi eve equi l i bri um as the
HETP for that segment.
Convergence and Computing Time
RateFrac must sol ve many more equati ons for a gi ven col umn than an equi l i bri um
model . Computi ng ti mes for RateFrac are greater than they are for equi l i bri um
model s, parti cul arl y for probl ems contai ni ng many components. The sol uti on
al gori thm RateFrac uses i s an effi ci ent, Newton-based si mul taneous correcti on
approach. RateFrac sol uti on ti mes i ncrease wi th the square of the number of
components. Sol uti on ti mes can be an order of magni tude greater than RadFrac,
Mul ti Frac, or PetroFrac sol uti on ti mes for the same probl ems.
References for Built-In Correlations
RateFrac uses wel l -known and accepted correl ati ons to cal cul ate:
Bi nary mass transfer coeffi ci ents for the vapor and l i qui d phase
I nterfaci al areas
I n general , these quanti ti es depend on col umn di ameter and operati ng
parameters such as:
Vapor and l i qui d fl ow
Densi ti es
Vi scosi ti es
Surface tensi on of l i qui d
Vapor and l i qui d phase bi nary di ffusi on coeffi ci ents
Mass transfer coeffi ci ents and i nterfaci al areas depend on:
Packing characteristics Tray characteristics
Type (random or structured) Type (sieve, valve, or bubble-cap)
Size Weir and flow path length
Specific surface area Downcomer area
Material of construction Weir height
The correl ati ons i nvol ve wel l -defi ned di mensi onl ess groups, such as the
Reynol ds, Froude, Weber, Schmi dt, and Sherwood numbers. The correl ati ons
have been fi tted to experi mental measurements from l aboratory and pi l ot pl ant
absorpti on and di sti l l ati on col umns.
Versi on 10
Chapter 4
The correl ati ons RateFrac uses for mass transfer coeffi ci ents and i nterfaci al
areas are:
Column type Correlation used
Packed Columns (random packing) Onda et al. (1968)
Packed Columns (structured) Bravo et al. (1985, 1992)
Sieve Trays
Chan and Fair (1984)

Valve Trays Scheffe and Weiland (1987)
Bubble-Cap Trays
Grester et al. (1958)
These correlations do not provide the mass transfer coefficients and interfacial areas separately.
RateFrac al l ows you to wri te Fortran subrouti nes to cal cul ate:
Bi nary mass transfer coeffi ci ents
Heat transfer coeffi ci ents
I nterfaci al areas
The subrouti nes are descri bed i n the ASPEN PLUS User Models reference
manual .
By appl yi ng a ri gorous mul ti component mass transfer theory (Kri shna and
Standart, 1976), RateFrac uses bi nary mass transfer coeffi ci ents to eval uate:
Mul ti component bi nary mass transfer coeffi ci ents
Component mass transfer rates between vapor and l i qui d phases
RateFrac cal cul ates the vapor phase and l i qui d phase heat transfer coeffi ci ents
usi ng the Chi l ton-Col burn anal ogy (Ki ng, 1980). Thi s anal ogy rel ates:
Mass transfer coeffi ci ents
Heat transfer coeffi ci ents
Schmi dt number
Prandtl number
Mass and Heat Transfer Correlations
RateFrac uses several mass and heat transfer correl ati ons for :
Packed col umns.
Val ve Tray col umns
Bubbl e-Cap Tray col umns
Si eve Tray col umns
Packed Column
RateFrac cal cul ates the mass transfer coeffi ci ents and the i nterfaci al area
avai l abl e for mass transfer usi ng the correl ati ons devel oped by Onda et al ., 1968.
Versi on 10
Columns
The correl ati on for the l i qui d phase bi nary mass transfer coeffi ci ents i s:
( ) ( )
k
g
L
a
Sc a d
L
in
L
L L
in
L
p p
_
,
1
]
1
1
_
,

1 3 2 3
1 2
0 4
0 0051
/ /
/
.
.
The correl ati on for the gas phase bi nary mass transfer coeffi ci ent i s:
( ) ( )
k
RT
a D
G
a u
Sc a d
g
in
g
p in p g
in
g
p p
_
,
1
]
1
1
_
,
523
0 7
1 3
2
.
.
/
The i nterfaci al area avai l abl e for mass transfer i s gi ven by the correl ati on:
( )
[ ] { }
a a Re Fr We
p L L L c

1 145
0 1
0 05
0 2 0 75
exp .
.
.
. .
Where:
Re
L
a
L
p L
, Fr
a L
g
L
L
2
2
, We
L
a
L
p L
and:
k
L
in
= Bi nary mass transfer coeffi ci ent for the bi nary pai r i and n
i n the l i qui d phase (m/sec)
L
=
Densi ty of l i qui d (kg/m
3
)
g
=
Accel erati on due to gravi ty (m/sec
2
)
L
=
Vi scosi ty of l i qui d (Newton-sec/m
2
)
L =
Li qui d superfi ci al mass vel oci ty (kg/m
2
/sec)
a
w
=
Wetted i nterfaci al area (m
2
i nterfaci al area/m
3
packi ng
vol ume)
Sc
L
in
= Schmi dt number for the bi nary pai r i and n i n the l i qui d
phase =
( )
L L in
L
D
D
L
in
= Bi nary Maxwel l -Stefan di ffusi on coeffi ci ent for the bi nary
pai r i and n
(m
2
/sec)
a
p
= Speci fi c surface area of the packi ng
continued
Versi on 10
Chapter 4
d
p
= Nomi nal di ameter of packi ng or packi ng si ze (m)
k
g
in
i n the vapor phase (kg mol e/atm/m
2
/sec)
R =
Uni versal gas constant (m
3
atm/kg mol e/K)
T
g
= Gas phase temperature (K)
G =
Gas superfi ci al mass vel oci ty (kg/m
2
/sec)
g
=
Vi scosi ty of gas mi xture (Newton-sec/m
2
)
Sc
g
in
= Gas phase Schmi dt number for the bi nary pai r i and n =
( )

g g in
g
D
g
=
Densi ty of gas mi xture (kg/m
3
)
D
g
in
= Gas-phase bi nary Maxwel l -Stefan di ffusi on coeffi ci ent for
the bi nary pai r i and n (m
2
/sec)
= Surface tensi on (Newton/m)
c
= Cri ti cal surface tensi on of the packi ng materi al (Newton/m)
Valve Tray Column
RateFrac cal cul ates the mass transfer coeffi ci ents and the i nterfaci al area
avai l abl e for mass transfer usi ng the correl ati ons devel oped by Scheffe and
Wei l and, 1987.
The correl ati on for the l i qui d phase bi nary mass transfer coeffi ci ent i s:
( ) ( )
( )
( ) Sh Re Re v Sc
in
L
g L in
L
1254
0 68
0 09
0 05
0 5
.
.
.
.
.
The correl ati on for the gas phase bi nary mass transfer coeffi ci ents i s:
( ) ( )
( )
( ) Sh Re Re Sc
in
g
g L in
g
9 93
0 87
0 13
0 39
0 5
.
.
.
.
.
The i nterfaci al area avai l abl e for mass transfer i s gi ven by the correl ati on:
( ) ( )
( ) a Re
g L
027
0 37
0 25
0 52
.
.
.
.
Re
Versi on 10
Columns
Where:
Sh
k ad
D
in
L
L
in
L
L
in
, Sh
k ad
D
in
g
g
in
g
g
in
, Sc
D
in
L L
L
L
in
, Sc
D
in
g
g
g
g
in
,
Re
Ld
L
L
, Re
Gd
g
g
,
W
d
and:
L =
Li qui d mass vel oci ty (kg/m
2
/sec) (Vel oci ty i s based on tower
acti ve area.)
d = Geometri c parameter of uni t l ength (m)
L
=
Vi scosi ty of l i qui d mi xture (Newton-sec/m
2
)
G =
Gas mass vel oci ty (kg/m
2
/sec) (Vel oci ty i s based on tower
acti ve area.)
g
=
2
)
k
L
in
i n the l i qui d phase (kg mol e/m
2
/sec)
a =
I nterfaci al area (m
2
2
tower acti ve area)
L
=
Mol ar densi ty of l i qui d (kg mol e/m
3
)
D
L
in
pai r i and n
(m
2
/sec)
k
g
in
i n the vapor phase (kg mol e/m
2
/sec)
g
=
Mol ar densi ty of gas mi xture (kg mol e/m
3
)
D
g
in
2
/sec)
L
=
Densi ty of l i qui d mi xture (kg/m
3
)
g
=
3
)
W = Wei r hei ght (m)
Versi on 10
Chapter 4
Bubble-Cap Tray Column
RateFrac cal cul ates the product of the bi nary mass transfer coeffi ci ents and
i nterfaci al areas usi ng the correl ati ons devel oped by Grester et al ., 1958.
The product of l i qui d phase bi nary mass transfer coeffi ci ents and i nterfaci al area
i s gi ven by the correl ati on:
( )
) k a D F Lt
L
in
in
L
L
+ 4127 10 0 21313 015
8
0 5
. ( . .
.
The product of gas phase bi nary mass transfer coeffi ci ent and i nterfaci al area i s
gi ven by the correl ati on:
( )
( )
k a
h F Q
Sc
G
g
in
w L
in
g
+ + 0 776 4 567 0 2377 104 85

0 5
. . . .
.
Where:
k
L
in
2
/sec)
a =
2
2
tower acti ve area)
D
L
in
pai r i and n
(m
2
/sec)
F = F-Factor =

g g
1 2 /
kg / sec / m
1/2 1/2
_
,
g
=
Gas vol umetri c fl ow per uni t acti ve area (m
3
/sec/m
2
)
g
=
3
)
L =
Li qui d mol ar vel oci ty (kg mol e/m
2
/sec) (Vel oci ty i s based on
acti ve area.)
t
L
= Li qui d resi dence ti me =
0 9998 . / (sec) h Z Q
L L L
h
L
= Li qui d hol dup =
0 04191 019 2 0 0135 . . .4545 . ( ) + + h Q F m
w L
Z
L
= Li qui d fl ow path l ength (m)
continued
Versi on 10
Columns
Q
L
=
Li qui d fl ow per average path wi dth (m
3
/sec/m)
h
w
= Outl et wei r hei ght (m)
k
g
in
i n the vapor phase (kg mol e/m
2
/sec)
G =
Gas mol ar vel oci ty (kg mol e/m
2
acti ve area.)
Sc
g
in
= Gas-phase Schmi dt number for the bi nary pai r i and n =
( )

g g in
g
D
g
=
2
)
D
g
in
2
/sec)
Sieve Tray Column
RateFrac cal cul ates the product of mass transfer coeffi ci ents and i nterfaci al
areas usi ng the correl ati ons devel oped by Chan and Fai r, 1984.
The product of l i qui d phase bi nary mass transfer coeffi ci ent and i nterfaci al area
( )
( ) k a x D F Lt
L
in
in
L
L
+ 4127 10 0 21313 015
8
0 5
. . .
.
The product of the gas phase bi nary mass transfer coeffi ci ent and i nterfaci al area
( ) ( )
k a
D F F
h
g
in
in
g
L
0 5
2
0 5
1030 867
.
.
Where:
k
L
in
2
/sec)
a =
2
2
tower acti ve area)
D
L
in
pai r i and n
(m
2
/sec)
continued
Versi on 10
Chapter 4
F = F-Factor =
( )
g g
1 2 1 2 1 2 / / /
/ / kg sec m
g
=
Gas vol umetri c fl ow per uni t acti ve area (m
3
/sec/m
2
)
g
=
3
)
L =
Li qui d mol ar vel oci ty (kg mol e/m
2
acti ve area.)
t
L
= Li qui d resi dence ti me =
0 9998 . / (sec) h Z Q
L L L
h
L
= Li qui d hol dup =
0 04191 019 2 0 0135 . . .4545 . ( ) + + h Q F m
w L
Z
L
= Li qui d fl ow path l ength (m)
Q
L
=
Li qui d fl ow per average path wi dth (m
3
/sec/m)
h
w
= Outl et wei r hei ght (m)
k
g
in
i n the vapor phase (m/sec)
D
g
in
pai r i and n
(m
2
/sec)
F = Fracti onal approach to fl oodi ng gas vel oci ty =

g g
F /
g
F = Gas vel oci ty through acti ve area at fl oodi ng (m/sec)
h
L
= Li qui d hei ght =
( )
( )
e w e L e
h B Q +1533
2 3
/
/
m
e
=
( ) exp .
.
12 55
0 91
K
s
B =
( ) 0 0327 0 0286 137 8 . . exp . + h
K
s
=
( )
( )
g g L g
( ) / sec
.
0 5
m
L
=
Densi ty of l i qui d mi xture (kg/m
3
)
Versi on 10
Columns
Heat Transfer Coefficients
RateFrac cal cul ates the heat transfer coeffi ci ents, usi ng the Chi l ton-Col burn
anal ogy (Ki ng, 1980).
The heat transfer coeffi ci ent i s gi ven by:
( ) k Sc
h
Cp
av
tc
mix
2 3 /
Where:
k
av
= Average bi nary mass transfer coeffi ci ents (kg
mol e/sec)
Sc = Schmi dt number
h
tc
= Heat transfer coeffi ci ent (Watts/K)
Cp
mix
= Mol ar heat capaci ty (Joul es/kg mol e/K)
Pr = Prandtl number
Versi on 10
Chapter 4
References
Bravo, J.L., Rocha, J.A., and Fai r, J.R., "Mass Transfer i n Gauze Packi ngs,"
Hydrocarbon Processing, January, 91 (1985).
Bravo, J.L., Rocha, J.A., and Fai r, J.R., "A Comprehensi ve Model for the
Performance of Col umns Contai ni ng Structured Packi ngs," I CHEME Symposi um
Seri es, 128, A439 (1992).
Chan, H. and Fai r, J.R., "Predi cti on of Poi nt Effi ci enci es i n Si eve Trays: 1. Bi nary
Systems, 2. Mul ti component Systems," I nd. Eng. Chem. Process Des. Dev., 23,
(1984) p. 814.
Grester, J.A., Hi l l , A.B., Hochgraf, N.N., and Robi nson, D.G., "Tray Effi ci enci es
i n Di sti l l ati on Col umns," AI ChE Report, (1958).
Ki ng, C.J., Separation Processes, Second Edi ti on, McGraw-Hi l l Company, (1980).
Kri shna, R. and Standart, G.L., "A Mul ti component Fi l m Model I ncorporati ng a
General Matri x Method of Sol uti on to the Maxwel l -Stefan Equati ons," AI ChE J .,
22, (1976) p. 383.
Onda, K., Takeuchi , H., and Okumoto, Y., "Mass Transfer Coeffi ci ents between
Gas and Li qui d Phases i n Packed Col umns," J . Chem. Eng., J apan, 1, (1968) p.
56.
Perry, R.H. and Chi l ton, C.H., "Chemi cal Engi neers Handbook," Fi fth Edi ti on,
McGraw-Hi l l Book Company, Secti on 18 (1973).
Scheffe, R.D. and Wei l and, R.H., "Mass Transfer Characteri sti cs of Val ve Trays,"
I nd. Eng. Chem. Res., 26, (1987) p. 228.
Versi on 10
Columns
Versi on 10
Chapter 4
Extract
Rigorous Extraction
Extract i s a ri gorous model for si mul ati ng l i qui d-l i qui d extractors. I t can have
mul ti pl e feeds, heater/cool ers, and si de streams. Extract can cal cul ate
di stri buti on coeffi ci ents usi ng:
An acti vi ty coeffi ci ent model or equati on of state capabl e of representi ng two
l i qui d phases
A bui l t-i n temperature-dependent correl ati on (KLL Correl ati on sheet)
A Fortran subrouti ne (KLL Subrouti ne sheet)
Al though equi l i bri um stages are assumed, you can speci fy component or stage
separati on effi ci enci es. Extract can be used onl y for rati ng cal cul ati ons.
You can defi ne pseudoproduct streams (Report PseudoStreams sheet) to
represent extractor i nternal fl ows. You can use Fortran and sensi ti vi ty bl ocks to
vary confi gurati on parameters, such as feed l ocati on or number of stages.
Flowsheet Connectivity for Extract
L1 Phase
L1 Phase
L2 Phase
Side products
(any number) (any number)
Side feeds
L2 Phase
Nstage
1
Material Streams
Inlet One materi al stream to the fi rst (top) stage, ri ch i n the fi rst l i qui d phase
(L1)
One materi al stream to the l ast (bottom) stage, ri ch i n the second l i qui d
phase (L2)
One materi al stream per i ntermedi ate stage (opti onal )
Outlet One materi al stream for L1 from the l ast stage
One materi al stream for L2 from the fi rst stage
Up to two si de product streams per stage, one for L1 and one for L2
(opti onal )
Versi on 10
Columns
Specifying Extract
Extract can operate i n one of the fol l owi ng ways:
Adi abati cal l y (defaul t)
At a speci fi ed temperature
Wi th speci fi ed stage heater or cool er duti es
You must speci fy:
Number of stages
Feed and product stream stage l ocati ons
Si de product stream phase and mol e fl ow rate
Pressure profi l e
The fi rst l i qui d phase (L1) fl ows from the fi rst stage to the l ast stage. The second
(L2) fl ows i n the opposi te di recti on. You must i denti fy the key components i n each
phase usi ng L1-Comps and L2-Comps on the Setup form. Extract can treat phase
L1 as the sol vent/extract phase or the feed/raffi nate phase.
Li qui d-l i qui d di stri buti on coeffi ci ents are requi red to represent the l i qui d-l i qui d
equi l i bri um. Extract cal cul ates these coeffi ci ents usi ng one of the fol l owi ng
methods:
You can use You enter On sheet
Any physical property method that can
represent two liquid phases
A global property method or an Opset
name to override the global physical
property method
BlockOptions Properties
A built-in temperature-dependent
polynomial
Polynomial coefficients Properties KLL Correlation
A Fortran subroutine Subroutine name Properties KLL Subroutine
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Extract:
Efficiencies Specify stage or component efficiencies
Properties Specify parameters for KLL correlations and KLL subroutines
Estimates Specify initial estimates for stage temperatures and compositions
Convergence Specify convergence parameters and block-specific diagnostic message levels
Report Specify block-specific report options and pseudostream information
continued
Versi on 10
Chapter 4
Results View column performance summary, material and energy balance results, and split
fractions
Profiles View extractor profiles
See ASPEN PLUS User Models for more i nformati on about Fortran subrouti nes.
O O O O
Versi on 10
Columns
Versi on 10
Chapter 5
5 Reactors
Thi s chapter descri bes the uni t operati on model s for reactors. The model s are:
RStoic Stoichiometric reactor Models stoichiometric
reactor with specified
reaction extent or
conversion
Reactors where reaction kinetics are unknown
or unimportant but stoichiometry and extent of
reaction are known
RYield Yield reactor Models reactor with
specified yield
Reactors where stoichiometry and kinetics are
unknown or unimportant but a yield distribution
is known
REquil Equilibrium reactor Performs chemical and
phase equilibrium by
stoichiometric calculations
Reactors with simultaneous chemical
equilibrium and phase equilibrium
RGibbs Equilibrium reactor with
Gibbs energy minimization
Performs chemical and
phase equilibrium by Gibbs
energy minimization
Reactors with phase equilibrium or
simultaneous phase and chemical equilibrium.
Calculating phase equilibrium for solid
solutions and vapor-liquid-solid systems.
RCSTR Continuous stirred tank
reactor
Models continuous stirred
tank reactor
One-, two, or three-phase stirred tank reactors
with rate-controlled and equilibrium reactions in
any phase based on known stoichiometry and
kinetics
RPlug Plug flow reactor Models plug flow reactor One-, two-, or three-phase plug flow reactors
with rate-controlled reactions in any phase
based on known stoichiometry and kinetics
RBatch Batch reactor Models batch or semi-batch
reactor
One-, two-, or three-phase batch and semi-
batch reactors with rate-controlled reactions in
any phase based on known stoichiometry and
kinetics
RCSTR, RPl ug, and RBatch are ki neti c reactor model s. Use the Reacti ons
Reacti ons form to defi ne the reacti on stoi chi ometry and data for these model s.
Versi on 10
Reactors
You do not need to speci fy heats of reacti on, because ASPEN PLUS uses the
el emental enthal py reference state for the defi ni ti on of the component heat of
formati on. Therefore, heats of reacti on are accounted for i n the mi xture enthal py
cal cul ati ons for the reactants versus the products.
RStoic
Stoichiometric Reactor
Use RStoi c to model a reactor when:
Reacti on ki neti cs are unknown or uni mportant and
Stoi chi ometry and the mol ar extent or conversi on i s known for each reacti on
RStoi c can model reacti ons occurri ng si mul taneousl y or sequenti al l y. I n addi ti on,
RStoi c can perform product sel ecti vi ty and heat of reacti on cal cul ati ons.
Flowsheet Connectivity for RStoic
Material
Water (optional)
Heat (optional)
Material
(any number)
Heat
(optional)
Material Streams
Outlet One product stream
Versi on 10
Chapter 5
Heat Stream
RStoi c uses the sum of the i nl et heat streams as the heat duty speci fi cati on, i f
you do not speci fy an outl et heat stream.
The val ue of the outl et heat stream i s the net heat duty (sum of the i nl et heat
streams mi nus the cal cul ated heat duty) for the reactor.
Specifying RStoic
Use the Setup Speci fi cati ons sheet to speci fy the reactor operati ng condi ti ons and
to sel ect the phases to consi der i n fl ash cal cul ati ons i n the reactor.
Use the Setup Reacti ons sheet to defi ne the reacti ons occurri ng i n the reactor.
You must speci fy the stoi chi ometry for each reacti on. I n addi ti on, you must
speci fy ei ther the mol ar extent or the fracti onal conversi on for al l reacti ons.
When sol i ds are created or changed by the reacti ons, you may speci fy the
component attri butes and the parti cl e si ze di stri buti on i n the outl et stream usi ng
the Setup Component Attr. sheet and the Setup PSD sheet respecti vel y.
I f you wi sh to cal cul ate the heats of reacti on, use the Setup Heat of Reacti on
sheet to speci fy the reference component for each reacti on defi ned i n the Setup
Reacti ons sheet. You may al so choose to speci fy the heats of reacti on, and RStoi c
adjusts the cal cul ated reactor duty, i f needed.
I f you wi sh to cal cul ate product sel ecti vi ti es use the Setup Sel ecti vi ty sheet to
speci fy the sel ected product component and the reference reactant component.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RStoi c:
Setup Specify operating conditions, reactions, reference conditions for heat of reaction
calculations, product and reactant components for selectivity calculations, particle size
distribution, and component attributes
Convergence Specify estimates and convergence parameters for flash calculations
Results View summary of operating results, mass and energy balances, heats of reaction,
product selectivities, reaction extents, and phase equilibrium results for the outlet
stream
Versi on 10
Reactors
Heat of Reaction
RStoi c cal cul ates the heat of reacti on from the heats of formati on i n the
databanks when you sel ect the Cal cul ate Heat of Reacti on opti on on the Setup
Heat of Reacti on sheet. The heats of reacti on are cal cul ated at the speci fi ed
reference condi ti ons based on consumpti on of a uni t mol e or mass of the reference
reactant sel ected for each reacti on. The fol l owi ng reference condi ti ons are used
by defaul t:
Specification Default
Reference temperature 25 C
Reference pressure 1 atm
Reference fluid phase Vapor phase
You can al so use the Setup Heat of Reacti on sheet to speci fy the heats of
reacti on. The speci fi ed heat of reacti on may di ffer from the heat of reacti on that
ASPEN PLUS computes from the heats of formati on at reference condi ti ons. I f
thi s occurs, RStoi c adjusts the cal cul ated reactor heat duty to refl ect the
di fferences. Under these ci rcumstances, the cal cul ated reactor heat duty wi l l not
be consi stent wi th the i nl et and outl et stream enthal pi es.
Selectivity
The sel ecti vi ty of the sel ected component P to the reference component A i s
defi ned as:
S
P
A
P
A
P A ,
1
]
1
1
]
1
Real
Ideal
Where:
P = Change i n number of mol es of component P due to reacti on
A = Change i n number of mol es of component A due to reacti on
I n the numerator, real represents changes that actual l y occur i n the reactor.
ASPEN PLUS obtai ns thi s val ue from the mass bal ance between the i nl et and
outl et.
Versi on 10
Chapter 5
I n the denomi nator, ideal represents changes accordi ng to an i deal i zed reacti on
scheme. Thi s scheme assumes that no reacti ons are present, except for the
reacti on that produces the sel ected component from the reference component.
Therefore, the denomi nator i ndi cates how many mol es of P are produced per
mol e of A consumed i n an i deal stoi chi ometri c equati on, or:
P
A
Ideal
P
A
1
]
1
where
A
and
P
are stoi chi ometri c coeffi ci ents.
Thi s exampl e shows how RStoi c cal cul ates sel ecti vi ty:
a1 A + b1 B c1 C + d1 D
c2 C + e2 E p2 P
a3 A + f3 F q3 Q
The sel ecti vi ty of P to A i s:
S
Moles of P produced
Moles of A consumed
c p
a c
P A ,
/
1
]
1
1
]
1
1 2
1 2
I n most cases, sel ecti vi ty ranges between 0 and 1. However, i f the sel ected
component i s al so produced from components other than the reference
component, sel ecti vi ty may be greater than 1. I f the sel ected component i s
consumed i n other reacti ons, sel ecti vi ty may be l ess than 0.
Versi on 10
Reactors
RYield
Yield Reactor
Use RYi el d to model a reactor when:
Reacti on stoi chi ometry i s unknown or uni mportant
Reacti on ki neti cs are unknown or uni mportant
Yi el d di stri buti on i s known
You must speci fy the yi el ds (per mass of total feed, excl udi ng any i nert
components) for the products or cal cul ate them i n a user-suppl i ed Fortran
subrouti ne. RYi el d normal i zes the yi el ds to mai ntai n a mass bal ance. RYi el d can
model one-, two-, and three-phase reactors.
Flowsheet Connectivity for RYield
Material
Water (optional)
Heat (optional)
Material
(any number)
Heat
(optional)
Material Streams
Outlet One product stream
Heat Streams
Versi on 10
Chapter 5
I f you gi ve onl y one speci fi cati on on the Setup Speci fi cati ons sheet (temperature
or pressure), RYi el d uses the sum of the i nl et heat streams as a duty
speci fi cati on. Otherwi se, RYi el d uses the i nl et heat stream(s) onl y to cal cul ate
the net heat duty. The net heat duty i s the sum of the i nl et heat streams mi nus
the actual (cal cul ated) heat duty.
You can use an outl et heat stream for the net heat duty.
Specifying RYield
Use the Setup Speci fi cati ons and Setup Yi el d sheets to speci fy the reactor
condi ti ons and the component yi el ds. For each reacti on product, speci fy the yi el d
as ei ther mol es or mass of a component per uni t mass of feed. I f you speci fy i nert
components on the Setup Yi el d sheet, the yi el ds wi l l be based on uni t mass of
non-i nert feed.
Cal cul ated yi el ds are normal i zed to mai ntai n an overal l materi al bal ance. For
thi s reason, yi el d speci fi cati ons establ i sh a yi el d di stri buti on, rather than
absol ute yi el ds. RYi el d does not mai ntai n atom bal ances because you enter the
fi xed yi el d di stri buti on.
You can request one-, two-, or three-phase cal cul ati on.
When sol i ds are created or changed by the reacti ons, you can speci fy thei r
component attri butes and/or parti cl e si ze di stri buti on i n the outl et stream usi ng
the Setup Component Attr. and Setup PSD sheets, respecti vel y.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RYi el d:
Setup Specify reactor operating conditions, component yields, inert components, flash
convergence parameters, and PSD and component attributes for the outlet stream
UserSubroutine Specify subroutine name and parameters for the user-supplied yield subroutine
Results View summary of operating results, mass and energy balances for the reactor and
phase equilibrium results for the outlet stream
Versi on 10
Reactors
REquil
Equilibrium Reactor
Use REqui l to model a reactor when:
Reacti on stoi chi ometry i s known and
Some or al l reacti ons reach chemi cal equi l i bri um
REqui l cal cul ates si mul taneous phase and chemi cal equi l i bri um. REqui l al l ows
restri cted chemi cal equi l i bri um speci fi cati ons for reacti ons that do not reach
equi l i bri um. REqui l can model one- and two-phase reactors.
Flowsheet Connectivity for REquil
Heat (optional)
Material (vapor phase)
Material (liquid phase)
Material
(any number)
Heat
(optional)
Material Streams
One materi al stream for the l i qui d phase
Heat Streams
I f you gi ve onl y one speci fi cati on on the REqui l I nput Speci fi cati ons sheet
(temperature or pressure), REqui l uses the sum of the i nl et heat streams as a
duty speci fi cati on. Otherwi se, REqui l uses the i nl et heat stream(s) onl y to
cal cul ate the net heat duty. The net heat duty i s the sum of the i nl et heat
streams mi nus the actual (cal cul ated) heat duty.
Versi on 10
Chapter 5
Specifying REquil
You must speci fy the reacti on stoi chi ometry and the reactor condi ti ons. I f no
addi ti onal speci fi cati ons are gi ven, REqui l assumes that the reacti ons wi l l reach
equi l i bri um.
REqui l cal cul ates equi l i bri um constants from the Gi bbs energy. You can restri ct
the equi l i bri um by speci fyi ng one of the fol l owi ng:
The mol ar extent for any reacti on
A temperature approach to chemi cal equi l i bri um (for any reacti on)
I f you speci fy temperature approach, T, REqui l eval uates the chemi cal
equi l i bri um constant at T + T, where T i s the reactor temperature (speci fi ed or
cal cul ated).
REqui l performs si ngl e-phase property cal cul ati ons or two-phase fl ash
cal cul ati ons nested i nsi de a chemi cal equi l i bri um l oop. REqui l cannot perform
three-phase cal cul ati ons.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for REqui l :
Input Specify reactor operating conditions, valid phases, reactions, convergence
parameters, and solid and liquid entrainment in the vapor stream
Results View summary of operating results, mass and energy balances, and calculated
chemical equilibrium constants
Solids
Reacti ons can i ncl ude conventi onal sol i ds. REqui l treats each parti ci pati ng sol i d
component as a separate pure sol i d phase, not as a component i n a sol i d sol uti on.
Any parti ci pati ng sol i ds must have a free energy formati on (DGSFRM) and
enthal py of formati on (DHSFRM), or heat capaci ty parameters (CPSXP1).
Sol i ds not parti ci pati ng i n reacti ons, i ncl udi ng any nonconventi onal components,
are treated as i nert. These sol i ds have no effect on the equi l i bri um cal cul ati ons
except on the energy bal ance.
Versi on 10
Reactors
RGibbs
Equilibrium Reactor (Gibbs Free Energy Minimization)
RGi bbs uses Gi bbs free energy mi ni mi zati on wi th phase spl i tti ng to cal cul ate
equi l i bri um. RGi bbs does not requi re that you speci fy the reacti on stoi chi ometry.
Use RGi bbs to model reactors wi th:
Si ngl e phase (vapor or l i qui d) chemi cal equi l i bri um
Phase equi l i bri um (an opti onal vapor and any number of l i qui d phases) wi th
no chemi cal reacti ons
Phase and/or chemi cal equi l i bri um wi th sol i d sol uti on phases
Si mul taneous phase and chemi cal equi l i bri um
RGi bbs can al so cal cul ate the chemi cal equi l i bri a between any number of
conventi onal sol i d components and the fl ui d phases. RGi bbs al so al l ows
restri cted equi l i bri um speci fi cati ons for systems that do not reach compl ete
equi l i bri um.
Flowsheet Connectivity for RGibbs
Material
(any number)
Material
(any number)
Heat
(optional)
Heat
(optional)
Material Streams
Outlet At l east one materi al stream
I f you speci fy as many outl et streams as the number of phases that RGi bbs
cal cul ates, RGi bbs assi gns each phase to an outl et stream. I f you speci fy fewer
outl et streams, RGi bbs assi gns the addi ti onal phases to the l ast outl et stream.
Versi on 10
Chapter 5
Heat Streams
I f you speci fy onl y pressure on the Setup Speci fi cati ons sheet, RGi bbs uses the
sum of the i nl et heat streams as a duty speci fi cati on. Otherwi se, RGi bbs uses the
i nl et heat stream(s) onl y to cal cul ate the net heat duty. The net heat duty i s the
Specifying RGibbs
Thi s secti on descri bes how to speci fy:
Phase equi l i bri um onl y
Phase and chemi cal equi l i bri um
Restri cted chemi cal equi l i bri um
Reacti ons
Sol i ds
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RGi bbs:
Setup Specify reactor operating conditions and phases to consider in equilibrium
calculations, identify possible products, assign phases to outlet streams, specify
inert components and specify equilibrium restrictions.
Advanced Specify atomic formula of components, estimates for temperature and component
flows, and convergence parameters.
message levels and report options for this block.
Results View summary of operating results, mass and energy balances, molar
compositions of fluid and solid phases present, the atomic formula of
components, and calculated reaction equilibrium constants.
Versi on 10
Reactors
Phase Equilibrium Only
To specify Use this option On
Phase equilibrium
calculations only
Phase Equilibrium Only Setup Specifications sheet
Maximum number of fluid
phases that RGibbs should
consider
Maximum Number of Fluid
Phases
Setup Specifications sheet
Maximum number of solid
solution phases
Maximum Number of Solid
Solution Phases
Solid Phases dialog box from the Setup
Specifications sheet
RGi bbs di stri butes al l speci es among al l sol uti on phases by defaul t. You can use
the Setup Products sheet to assi gn di fferent sets of speci es to each sol uti on
phase. You can al so assi gn di fferent thermodynami c property methods to each
phase.
I f there i s a possi bi l i ty that a sol i d sol uti on phase may exi st, use the Setup
Products sheet to i denti fy the speci es that wi l l exi st i n that phase.
Phase Equilibrium and Chemical Equilibrium
To specify Use this option On
Chemical equilibrium
calculations (with or without
phase equilibrium)
Phase Equilibrium and
Chemical Equilibrium
Maximum number of fluid
phases that RGibbs should
consider
Maximum Number of Fluid
Phases
Maximum number of solid
solution phases
Maximum Number of Solid
Solution Phases
Solid Phases dialog box from the Setup
Specifications sheet
By defaul t, RGi bbs consi ders al l components entered on the Components
Speci fi cati ons Sel ecti on sheet as possi bl e fl ui d phase or sol i d products. You can
speci fy an al ternate l i st of products on the Setup Products sheet.
RGi bbs di stri butes al l sol uti on speci es among al l sol uti on phases by defaul t. You
can use the Setup Products sheet to assi gn di fferent sets of speci es to each
sol uti on phase. You can al so assi gn di fferent thermodynami c property methods to
each phase.
Versi on 10
Chapter 5
RGi bbs needs the mol ecul ar formul a for each component that i s present i n a feed
or product stream. RGi bbs retri eves thi s i nformati on from the component
databanks. For non-databank components, use the Properti es Mol ec-Struct
Formul a sheet to enter:
Atom (the atom type)
Number of occurrences (the number of atoms of each type)
Al ternati vel y, you can enter the atom matri x on the Advanced Atom Matri x
sheet. The atom matri x defi nes the number of each atom i n each component. I f
you enter the atom matri x, you must enter i t for al l components and atoms,
i ncl udi ng databank components.
I f there i s a possi bi l i ty that a sol i d sol uti on phase may exi st, use the Setup
Products sheet to i denti fy the speci es whi ch wi l l exi st i n that phase.
Restricted Chemical Equilibrium
To restri ct chemi cal equi l i bri um:
Specify On
The molar extent of the reaction Edit Reactions dialog box (from the Setup
RestrictedEquilibrium sheet)
A temperature approach to equilibrium for individual reactions Edit Reactions dialog box (from the Setup
A temperature approach to chemical equilibrium for the entire system Edit Reactions dialog box (from the Setup
The outlet amount of any component as total mole flow or as a fraction of
the feed of that component
Setup Inerts sheet
You can specify inert components by setting the fraction to 1.

For temperature approach speci fi cati ons, RGi bbs eval uates the chemi cal
equi l i bri um constant at T T + , where T i s the actual reactor temperature
(speci fi ed or cal cul ated) and T i s the desi red temperature approach.
You can enter one of the fol l owi ng restri cted equi l i bri um speci fi cati ons for
i ndi vi dual reacti ons:
The mol ar extent of a reacti on
The temperature approach for an i ndi vi dual reacti on
Use the Setup Restri ctedEqui l i bri um sheet to suppl y the reacti on stoi chi ometry.
I f you enter one of the precedi ng speci fi cati ons, you must al so suppl y the
stoi chi ometry for a set of l i nearl y i ndependent reacti ons i nvol vi ng al l components
i n the system.
Versi on 10
Reactors
Reactions
You can have RGi bbs consi der onl y a speci fi c set of reacti ons. You can restri ct the
chemi cal equi l i bri um by speci fyi ng temperature approach or mol ar extent for the
reacti ons. You must speci fy the stoi chi ometri c coeffi ci ents for a compl ete set of
l i nearl y i ndependent chemi cal reacti ons, even i f onl y one reacti on i s restri cted.
The number of l i nearl y i ndependent reacti ons requi red equal s the total number
of products i n the product l i st, i ncl udi ng sol i ds (see the Setup Products sheet),
mi nus the number of atoms present i n the system. The reacti ons must i nvol ve al l
parti ci pati ng components. A component i s parti ci pati ng i f i t sati sfi es these
cri teri a:
I t i s i n the product l i st.
I t i s not i nert. A component i s i nert i f i t consi sts enti rel y of atoms not present
i n any other product components.
I t has not been dropped. A component l i sted on the Setup Products sheet i s
dropped i f i t contai ns an atom not present i n the feed.
Solids
RGi bbs can cal cul ate the chemi cal equi l i bri a between any number of
conventi onal sol i d components and the fl ui d phases. RGi bbs detects whether the
sol i d i s present at equi l i bri um, and i f so, cal cul ates the amount. RGi bbs treats
each sol i d component as a pure sol i d phase, unl ess i t i s speci fi ed as a component
i n a sol i d sol uti on. Any sol i d that RGi bbs consi ders a product must have both:
Free energy of formati on (DGSFRM or CPSXP1)
Heat of formati on (DHSFRM or CPSXP1)
Nonconventi onal sol i ds are treated as i nert and have no effect on equi l i bri um
cal cul ati ons. I f chemi cal equi l i bri um i s not consi dered, RGi bbs treats al l sol i ds as
i nert. RGi bbs cannot perform sol i ds-phase-onl y cal cul ati ons.
RGi bbs pl aces al l pure sol i ds i n the l ast outl et stream unl ess you speci fy
otherwi se on the Setup Assi gnStreams sheet. RGi bbs can handl e onl y a si ngl e
CI SOLI D substream, whi ch contai ns al l conventi onal sol i ds products defi ned as
pure sol i d phases. RGi bbs pl aces the sol i d sol uti on phases i n the MI XED
substream of the outl et stream(s).
RGi bbs cannot di rectl y handl e phase equi l i bri um between sol i ds and fl ui d phases
(for exampl e, water-i ce equi l i bri um). To work around thi s, you can l i st the same
component twi ce on the Components Speci fi cati ons Sel ecti on sheet, wi th
di fferent component I Ds. I f you want RGi bbs to cal cul ate the chemi cal
equi l i bri um between these components:
Speci fy both component I Ds on the Setup Products sheet.
Desi gnate one I D as a sol i ds phase component, the other as a fl ui d phase
component.
Versi on 10
Chapter 5
References
Gautam, R. and Sei der, W.D., "Computati on of Phase and Chemi cal
Equi l i bri um," Parts I , I I , and I I I , AI ChE J . 25, 6, November, 1979, pp. 991-1015.
Whi te, C.W. and Sei der, W.D., "Computati on of Phase and Chemi cal
Equi l i bri um: Approach to Chemi cal Equi l i bri um," AI ChE J ., 27, 3, May, 1981,
pp. 446-471.
Schott, G. L., "Computati on of Restri cted Equi l i bri a by General Methods," J .
Chem. Phys., 40, 1964.
Versi on 10
Reactors
RCSTR
Continuous Stirred Tank Reactor
RCSTR ri gorousl y model s conti nuous sti rred tank reactors. RCSTR can model
one-, two-, or three-phase reactors. RCSTR assumes perfect mi xi ng i n the
reactor, that i s, the reactor contents have the same properti es and composi ti on as
the outl et stream.
RCSTR handl es ki neti c and equi l i bri um reacti ons as wel l as reacti ons i nvol vi ng
sol i ds. You can provi de the reacti on ki neti cs through the bui l t-i n Reacti ons
model s or through a user-defi ned Fortran subrouti ne.
Flowsheet Connectivity for RCSTR
Material
Heat (optional)
Material
(any number)
Heat
(optional)
Material Streams
Heat Streams
I f you speci fy onl y pressure on the Setup Speci fi cati ons sheet, RCSTR uses the
sum of the i nl et heat streams as a duty speci fi cati on. Otherwi se, RCSTR uses the
i nl et heat stream onl y to cal cul ate the net heat duty. The net heat duty i s the
Versi on 10
Chapter 5
Specifying RCSTR
You must speci fy the reactor operati ng condi ti ons, whi ch are pressure and ei ther
temperature or heat duty. You must al so enter the reactor vol ume or resi dence
ti me (overal l or phase).
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RCSTR:
Setup Specify reactor operating conditions and holdup, select the reaction sets to be included,
and specify PSD and component attributes in the outlet stream
Convergence Provide estimates for component flow rates, reactor temperature and volume, and specify
flash convergence parameters, RCSTR convergence methods and parameters, and
initialization options
UserSubroutine Specify parameters for the user-supplied kinetics subroutine and block-specific report
option for the kinetics subroutine
Results View summary of operating results and mass and energy balances for the block
Reactions
You must speci fy reacti on ki neti cs on the Reacti ons Reacti ons forms and sel ect
the Reacti on Set I D on the Setup Reacti ons sheet.
You can speci fy one-, two-, or three-phase cal cul ati ons. You can speci fy the phase
for each reacti on on the Reacti ons Reacti ons forms. RCSTR can handl e ki neti c
and equi l i bri um type reacti ons.
Phase Volume
I n a mul ti -phase reactor, by defaul t, ASPEN PLUS cal cul ates the vol ume of each
phase, usi ng phase equi l i bri um resul ts, as:
V V
V f
V f
Pi R
i i
j j
Where:
V
Pi
= Vol ume of phase i
V
R
= Reactor vol ume
V
i
= Mol ar vol ume of phase i
f
i
= Mol ar fracti on of phase i
Versi on 10
Reactors
You can overri de the defaul t cal cul ati on by speci fyi ng the vol ume of a phase
di rectl y (Phase Vol ume) or as a fracti on of the reactor vol ume (Phase Vol ume
Frac) on the Setup Speci fi cati ons sheet.
Al ternati vel y, when you speci fy the resi dence ti me of a phase i n the reactor,
ASPEN PLUS cal cul ates the phase vol ume i terati vel y.
Residence Time
ASPEN PLUS cal cul ates the resi dence ti me (overal l and phase) i n the CSTR as:
RT
V
F f V
R
i i
*
RT
V
F f V
i
Pi
i i
*
Where:
RT = Overal l resi dence ti me
RT
i
= Resi dence ti me of phase i
V
R
= Reactor vol ume
F = Total mol ar fl ow rate (outl et)
V
i
= Mol ar vol ume of phase i
f
i
= Mol ar fracti on of phase i
V
Pi
= Vol ume of phase i
When the defaul t cal cul ati on for phase vol ume, based on phase equi l i bri um
resul ts, i s used, the phase resi dence ti me i s equal for al l phases. I f you speci fy
Phase Vol ume or Phase Vol ume Frac on the Setup Speci fi cati ons sheet, the
resi dence ti me for the phase speci fi ed i n the Hol dup Phase i s cal cul ated wi th the
speci fi ed phase vol ume rather than the defaul t phase vol ume.
Solids
RCSTR can handl e reacti ons i nvol vi ng sol i ds. RCSTR assumes that sol i ds are at
the same temperature as the fl ui d phase. RCSTR cannot perform sol i ds-phase-
onl y cal cul ati ons.
Versi on 10
Chapter 5
Scaling of Variables
Four types of vari abl es are predi cted by RCSTR: component fl ow rates, stream
enthal py, component attri butes and PSD (i f present). RCSTR normal i zes these
vari abl es, for faster convergence, by di vi di ng each one by a scal e factor.
Two types of scal i ng are avai l abl e i n RCSTR: component-based scal i ng and
substream-based scal i ng. Component-based scal i ng wei ghs each vari abl e agai nst
i ts previ ous or esti mated val ue. Substream-based scal i ng wei ghs each vari abl e i n
a substream agai nst the substream fl ow rate. For component-based scal i ng,
mi ni mum scal e val ues are set by the Trace Scal i ng Factor i n the Advanced
Parameters di al og box (from the Convergence Parameters sheet). You may
reduce the trace scal i ng threshol d to i ncrease the predi cti on accuracy of trace
components.
Component-based scal i ng general l y provi des more accuracy than substream-
based scal i ng, especi al l y for trace components. Use component-based scal i ng
when:
The reacti on network i nvol ves trace i ntermedi ates
The reacti on rates are very sensi ti ve to trace reactants (such as catal ysts and
i ni ti ators whi ch parti ci pate i n degradati on reacti ons)
The fol l owi ng tabl es summari ze the scal e factors used by each method.
Substream-based Scaling Method
Variable Type Variable Initial Scale Factor
Component Flows Component mole flow in
outlet stream
Estimated outlet substream mole flow rate
Stream Enthalpy Net enthalpy flow of outlet
stream
Net enthalpy flow of inlet stream
Component Attributes
(attr/kg)
Product of component mass
flow (with attributes) and
attribute value in outlet
stream
Default attribute scale factor
PSD Product of substream mass
flow rate (with PSD) and
PSD value in outlet stream
Default attribute scale factor
Note I f any substream-based scal i ng factor i s equal to zero, the defaul t
scal i ng factor i s used i nstead (the defaul t factor i s 1.0 for
component fl ow rates and 1.0E5 for stream enthal py).
Versi on 10
Reactors
Component-based Scaling Method
Variable Type Variable Initial Scale Factor
Component Flows Component mole flow in
outlet stream
Larger of:
- Estimated component mole flow in outlet stream
- Product of Trace threshold and estimated outlet
substream mole flow
Stream Enthalpy Net enthalpy flow of outlet
stream
Net enthalpy flow of inlet stream
(attr/kg)
Product of component mass
flow with attributes and
attribute value in outlet
stream
Larger of:
- Product of estimated attributed component mass flow
and estimated attribute value in outlet stream
- Product of Trace threshold and estimated outlet
substream mole flow
PSD Product of substream mass
flow rate and PSD value in
outlet stream
Larger of:
- Product of estimated substream mass flow with PSDs
and estimated PSD value in outlet stream
- Product of Trace threshold and default attribute scale
factor
Versi on 10
Chapter 5
RPlug
Plug Flow Reactor
RPl ug i s a ri gorous model for pl ug fl ow reactors. RPl ug assumes that perfect
mi xi ng occurs i n the radi al di recti on and that no mi xi ng occurs i n the axi al
di recti on. RPl ug can model one-, two-, or three-phase reactors. You can al so use
RPl ug to model reactors wi th cool ant streams (co-current or counter-current).
RPl ug handl es ki neti c reacti ons, i ncl udi ng reacti ons i nvol vi ng sol i ds. You must
know the reacti on ki neti cs when you use RPl ug to model a reactor. You can
provi de the reacti on ki neti cs through the bui l t-i n Reacti ons model s or through a
user-defi ned Fortran subrouti ne.
Flowsheet Connectivity for RPlug
Material Material
Heat (optional)
Flowsheet Reactor without Coolant Stream
Material Material
Material Coolant
(optional)
Material Coolant
(optional)
Flowsheet Reactor with Coolant Stream
Versi on 10
Reactors
Material Streams
One cool ant stream (opti onal )
Outlet One materi al product stream
One cool ant stream (opti onal )
Heat Streams
Outlet One heat stream (opti onal ) for the reactor heat duty. Use the heat outl et
stream onl y for reactors wi thout a cool ant stream.
Specifying RPlug
Use the Setup Confi gurati on sheet to speci fy reactor tube l ength and di ameter. I f
the reactor consi sts of mul ti pl e tubes, you can al so speci fy the number of tubes.
You can speci fy the pressure drop across the reactor on the Setup Pressure sheet.
Addi ti onal requi red i nput for RPl ug depends on the reactor type.
When you use this
Reactor Type And solid phase is
And fluid and solid phase
temperatures are Specify
Reactor with specified
temperature
Reactor temperature, or
temperature profile
Adiabatic reactor Not present No required specifications
Present Same No required specifications
Present Different U (fluid phase - solids phase)
Reactor with constant coolant
temperature
Not present Coolant temperature, and
U (coolant - process stream)
Present Same Coolant temperature, and
Present Different Coolant temperature,
U (coolant - fluid phase),
U (coolant - solids phase),
and
U (fluid phase - solids phase)
Reactor with co-current
coolant
Not present U (coolant - process stream)
Present Same U (coolant - process stream)
continued
Versi on 10
Chapter 5
When you use this
Reactor Type And solid phase is
And fluid and solid phase
temperatures are Specify
Reactor with co-current
coolant
Not present U (coolant - process stream)
Present Same U (coolant - process stream)
Present Different U (coolant - fluid phase),
and
Reactor with counter-current
coolant
Not present Coolant outlet temperature or
molar vapor fraction, and
Present Same Coolant outlet temperature or
molar vapor fraction, and
Present Different Coolant outlet temperature or
molar vapor fraction,
U (coolant - fluid phase),
and
For reactors wi th countercurrent external cool ant, RPl ug cal cul ates the cool ant
i nl et temperature. The resul t overri des your speci fi ed i nl et cool ant temperature.
You can use a desi gn speci fi cati on that mani pul ates the cool ant exi t temperature
or vapor fracti on to achi eve a speci fi ed cool ant i nl et temperature.
For reactors wi th an external cool ant stream, you can use di fferent physi cal
property methods and opti ons (Bl ockOpti ons Properti es sheet) for the process
stream and the cool ant stream.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RPl ug:
Setup Specify operating conditions and reactor configuration, select reaction sets to be included,
and specify pressure drops
Convergence Specify flash convergence parameters, calculation options and parameters for the
integrator
Report Specify block-specific report options
UserSubroutine Specify user subroutine parameters for kinetics, heat transfer, pressure drop, and list user
variables to be included in the profile report
BlockOptions Override global values for property methods, simulation options, diagnostic levels, and
report options for this block
continued
Versi on 10
Reactors
Results View summary of operating results and mass and energy balances for the block
Profiles View profiles versus reactor length for process stream conditions, coolant stream
conditions, properties, component and substream attributes, and user variables
Reactions
You must speci fy reacti on ki neti cs on the Setup Reacti ons sheet, by referri ng to
Reacti on I Ds that you sel ect. You can speci fy one-, two-, or three-phase
cal cul ati ons. Speci fy the reacti on phases on the Reacti ons Reacti ons forms. RPl ug
can handl e onl y ki neti c type reacti ons.
Solids
Reacti ons can i nvol ve sol i ds. Sol i ds can be:
At the same temperature as the fl ui d phases
At a di fferent temperature from the fl ui d phases (onl y for Reactor Types other
than the reactor wi th speci fi ed temperature)
I n the l atter case, you must speci fy the heat transfer coeffi ci ents on the Setup
Versi on 10
Chapter 5
RBatch
Batch Reactor
RBatch i s a ri gorous model for batch or semi -batch reactors. Use RBatch when
you know the ki neti cs of the reacti ons taki ng pl ace. You can speci fy any number
of conti nuous feed streams. A conti nuous vent i s opti onal . The reacti on runs unti l
i t reaches a stop cri teri on that you speci fy.
Batch operati ons are unsteady-state processes. RBatch uses hol di ng tanks and
your speci fi ed cycl e ti mes to provi de an i nterface between the di screte operati ons
of the batch reactor and the conti nuous streams used by other model s.
RBatch can model one-, two-, or three-phase reactors.
Flowsheet Connectivity for RBatch
Vent
(optional)
Heat (optional)
Continuous feed
(any number)
Product
Batch charge
Material Streams
Inlet One batch charge stream (requi red)
One or more conti nuous feed streams for semi -batch reactors (opti onal )
Outlet One product stream (requi red)
One vent stream for semi -batch reactors (opti onal )
Heat Streams
Versi on 10
Reactors
Specifying RBatch
Use the Setup Speci fi cati ons sheet to speci fy the reactor condi ti ons.
Use the Setup Operati ons sheet to speci fy:
One or more stop cri teri a
Ei ther a feed ti me or a batch cycl e ti me
Other requi red i nput for RBatch depends on reactor type.
To establ i sh the pressure of the vessel , enter one of the fol l owi ng speci fi cati ons
on the Setup Speci fi cati ons sheet:
Constant pressure
Pressure profi l e
Reactor vol ume
Use the Setup Conti nuousFeeds sheet to enter mass fl ow rates for the conti nuous
feeds at any number of poi nts i n ti me. You can thus si mul ate del ayed feeds and
step changes i n feeds.
For speci fi ed duty reactors, you can speci fy ei ther a constant heat duty or a heat
duty profi l e. For a reactor wi th constant duty, RBatch assumes adi abati c
operati on i f you do not speci fy a heat duty.
For reactors wi th speci fi ed cool ant temperature, you must speci fy:
Cool ant temperature
An over-al l heat transfer coeffi ci ent
Total heat transfer area
For constant temperature and speci fi ed temperature reactors, RBatch handl es
the temperature speci fi cati on i n one of the fol l owi ng ways:
By assumi ng perfect control
By i nterpreti ng the speci fi ed temperature(s) as the setpoi nt(s) of a PI D
control l er
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for RBatch:
Setup Specify operating conditions, select reaction sets to be included, specify operation stop
criteria, operation times, continuous feeds, and controller parameters
Convergence Specify convergence parameters for flash calculations, integration, and pressure
calculations
Report Specify block-specific report options for profiles and reactor, vent, and vent accumulator
property profiles
UserSubroutine Specify parameters for the user kinetics subroutine, name and parameters for the user heat
transfer subroutine, and user variables for the profile report.
continued
Versi on 10
Chapter 5
Results View summary of block operating results and mass and energy balances
Profiles View time profiles of reactor conditions, compositions, continuous feed stream flows,
properties, component attributes, and user variables
Controller
RBatch assumes perfect control when one of these condi ti ons exi sts:
Pressure i n the reactor i s converged upon (that i s, reactor vol ume i s speci fi ed)
A si ngl e-phase batch reactor i s used wi th no conti nuous feed streams
I f RBatch cannot assume perfect control , i t i nterprets the speci fi ed
temperature(s) as the setpoi nt(s) of a PI D control l er. Thi s i nterpretati on occurs
when:
A two-phase reactor i s used
RBatch performs pressure convergence cal cul ati ons (that i s, reactor vol ume i s
speci fi ed)
Conti nuous feeds are present duri ng semi -batch operati on
Use the Setup Control l ers sheet to speci fy the control l er tuni ng parameters.
The control l er equati on i s:
Q M K T T K I T T dt KD
d T T
dt
c
s s
s
t
+ +
1
]
1
( ) ( / ) ( )
( )
0
Where:
Q = Reactor heat duty (J/sec)
M
c
= Reactor charge (kg)
K = Proporti onal gai n (J/kg/K)
T = Reactor temperature (K)
T
s
= Temperature set poi nt (K)
I = I ntegral ti me (sec)
D = Deri vati ve ti me (sec)
t = Ti me (sec)
The gai n factor i s a speci fi c gai n per uni t mass.
Versi on 10
Reactors
Reactions
Reacti ons may or may not be present i n RBatch. I f they are, you must i ncl ude the
Reacti on Set I Ds on the Setup Reacti ons sheet. You can speci fy one-, two-, or
three-phase cal cul ati ons. You speci fy the reacti on phases on the Reacti ons
Reacti ons forms. RBatch can onl y handl e ki neti c type reacti ons.
Specifying Stop Criteria
A reacti on runs unti l one of your speci fi ed stop cri teri a reached. A stop cri teri on
can be one of the fol l owi ng:
Reacti on ti me
Reactor composi ti on
Vent accumul ator or conti nuous vent composi ti on
Conversi on of a component
Amount of materi al i n the reactor or vent accumul ator
Vent fl ow rate
Temperature i n the reactor
Vapor fracti on i n the reactor
Any property speci fi ed on the Properti es Prop-Sets Properti es sheet
As the stop cri teri on vari abl e approaches i ts cut-off from above or bel ow, you can
speci fy whether or not RBatch shoul d hal t the reacti on. I f you speci fy more than
one stop cri teri on, RBatch hal ts the reacti on as soon as one of the cri teri a i s
reached. I n addi ti on, you must speci fy a hal t ti me for the reacti on. I f the reacti on
does not reach the speci fi ed stop cri teri a by thi s ti me, RBatch hal ts the reacti on.
Cycle Time
You can speci fy a reactor cycl e ti me. Or, you can l et RBatch cal cul ate i t from your
speci fi ed reacti on and down ti mes for drai ni ng, cl eani ng, and chargi ng the
reactor. I f you do not speci fy reactor cycl e ti me, then speci fy a feed cycl e ti me.
RBatch uses thi s ti me to determi ne the batch charge, because the reacti on ti me
i s not known at the begi nni ng of bl ock executi on.
Note I f the reactor batch charge stream i s i n a recycl e l oop, you must
speci fy the reactor cycl e ti me.
Mass Balances
Because RBatch uses di fferent cycl e ti mes to cal cul ate ti me-averaged fl ows,
RBatch may not mai ntai n a mass bal ance around the bl ock. For exampl e,
suppose you speci fy a feed ti me of 30 mi nutes, but the down ti me pl us the
cal cul ated val ue reacti on ti me equal s 45 mi nutes. The resul ti ng net mass fl ow
from the reactor i s l ess than the charge fl ow by a factor of 45/30=1.5.
Versi on 10
Chapter 5
Remember that the mass bal ance pertai ns to the ti me-averaged i nl et and outl et
conti nuous streams. RBatch al ways sati sfi es a mass bal ance for i ts own i nternal
batch computati ons. I f there i s no conti nuous feed stream, the mass bal ance
around RBatch cl oses onl y i f the cycl e ti me i s speci fi ed. Thi s ensures that the
same ti me i s used for averagi ng the batch change and product streams. I f there i s
a conti nuous feed stream, and i t i s not ti me-varyi ng, the mass bal ance cl oses onl y
i f the cycl e ti me i s speci fi ed, and the speci fi ed val ue i s equal to the cal cul ated
reacti on ti me. I n al l other cases, the mass bal ance around RBatch does not cl ose,
al though the composi ti ons, temperature, and so on are correct.
Batch Operation
RBatch can operate i n a batch or i n semi -batch mode. The reactor mode i s
determi ned by the streams you enter on the fl owsheet. A semi -batch reactor can
have a vent product stream, one or more conti nuous feed streams, or both. The
vent product stream exi ts a vent accumul ator. I t does not exi t the reactor i tsel f.
The vent accumul ator i s for the conti nuous (but ti me-varyi ng) vapor vent l eavi ng
the reactor. The composi ti on and temperature of each conti nuous feed stream
remai n constant throughout the reacti on. The fl ow rate al so remai ns constant,
unl ess you speci fy a ti me profi l e for the fl ow rate of a conti nuous stream.
Batch operati ons are unsteady-state processes. Vari abl es l i ke temperature,
composi ti on, and fl ow rate change wi th ti me, i n contrast to steady-state
processes. To i nterface RBatch wi th a steady-state fl owsheet, i t i s necessary to
use ti me-averaged streams.
Four types of streams are associ ated wi th RBatch, as fol l ows:
Batch Charge The materi al transferred to the reactor at the start of the
reactor cycl e. The mass of the batch charge equal s the fl ow rate of the batch
charge stream, mul ti pl i ed by the feed cycl e ti me. The mass of the batch charge i s
equi val ent to accumul ati ng the batch charge stream i n a hol di ng tank duri ng a
reactor cycl e. The contents of the hol di ng tank are transferred to the reactor at
the begi nni ng of the next cycl e . (See fi gure RBatch Reactor Confi gurati on - No
Vent Case.)
To compute the amount of the batch charge, RBatch mul ti pl i es the fl owsheet
stream representi ng the batch charge by a cycl e ti me you enter (ei ther Cycl e
Ti me or Batch Feed Ti me). Batch Feed Ti me i s not the ti me requi red to charge
the reactor; i t i s a total cycl e ti me used onl y to compute the amount of the charge.
Batch Feed Ti me i s requi red when Cycl e Ti me i s unknown.
I f Batch Feed Ti me di ffers from the actual computed cycl e ti me, the RBatch
fl owsheet i nl et and outl et streams are not i n mass bal ance. However, al l i nternal
RBatch cal cul ati ons and reports wi l l be correct for the computed batch charge.
Versi on 10
Reactors
Conti nuous Feed A steady-state fl owsheet stream fed conti nuousl y to the
reactor duri ng reacti on. I ts composi ti on and temperature remai n constant
throughout the reacti on. I ts fl ow rate ei ther remai ns constant or fol l ows a
speci fi ed ti me profi l e.
Reactor Product The materi al l eft i n the reactor at the end of the reactor
cycl e. The fl ow rate of the reactor product stream equal s the total mass i n the
reactor, di vi ded by the reactor cycl e ti me. You can thi nk of thi s process as
anal ogous to transferri ng the reactor product to a product hol di ng tank. Thi s
tank i s drawn down duri ng the next reactor cycl e to feed the conti nuous bl ocks
downstream (see fi gure RBatch Reactor Confi gurati on - No Vent Case ).
Vent Product The contents of the vent accumul ator at the end of the reactor
cycl e. Duri ng the reactor cycl e, the ti me-varyi ng vent stream accumul ates i n the
vent accumul ator (see fi gure RBatch Reactor Confi gurati on - Vent Case). The
fl ow rate of the vent product stream i s the total mass i n the vent accumul ator,
di vi ded by the reactor cycl e ti me.
Feed
Holding
Tank
Flowsheet
Stream for
Batch
Charge
Batch charge
transferred
once each
cycle
Product
Holding
Tank
Reactor
product
transferred
once each
cycle
Flowsheet
Stream for
Reactor
Product
Reactor
RBatch Reactor ConfigurationNo Vent Case
Versi on 10
Chapter 5
Feed
Holding
Tank
Flowsheet
Stream for
Batch
Charge
Batch charge
transferred
once each
cycle
Product
Holding
Tank
Reactor
product
transferred
once each
cycle
Flowsheet
Stream for
Reactor
Product
Vent
Holding
Tank
Vent
Accumulator
Vent
Product
transferred
once per
cycle
Flowsheet
Stream for
Vent
Product
Reactor
Optional Flowsheet
Stream for
Continuous Feed
RBatch Reactor ConfigurationVent Case
O O O O
Versi on 10
Reactors
Versi on 10
Chapter 6
6 Pressure Changers
Thi s chapter descri bes the uni t operati on model s for pumps and compressors,
and model s for cal cul ati ng pressure change through pi pes and val ves. The model s
are:
Pump Pump or hydraulic turbine Changes stream pressure
when the power requirement
is needed or known
Pumps and hydraulic turbines
Compr Compressor or turbine Changes stream pressure
when power requirement is
needed or known
Polytropic compressors, polytropic positive
displacement compressors, isentropic
compressors, isentropic turbines
MCompr Multistage compressor or
turbine
Changes stream pressure
across multiple stages with
intercoolers. Allows for liquid
knockout streams from
intercoolers
Multistage polytropic compressors, polytropic
positive displacement compressors, isentropic
compressors, isentropic turbines
Valve Valve pressure drop Models pressure drop
through a valve
Control valves and pressure changers
Pipe Single segment pipe Models pressure drop
through a single segment of
pipe
Pipe with constant diameter (may include
fittings)
Pipeline Multiple segment pipeline Models pressure drop
through a pipe or annular
space
Pipeline with multiple lengths of different
diameter or elevation
Use Pump, Compr, and MCompr model s when energy-rel ated i nformati on such as
power requi rement i s needed or known.
Versi on 10
Pressure
Changers
Pump
Pump/Hydraulic Turbine
Use Pump to model a pump or a hydraul i c turbi ne.
Pump i s desi gned to handl e a si ngl e l i qui d phase. For speci al cases, you can
speci fy two- or three-phase cal cul ati ons to determi ne the outl et stream condi ti ons
and to compute the fl ui d densi ty used i n the pump equati ons. The accuracy of the
resul ts depends on a number of factors, such as the rel ati ve amounts of the
phases present, the compressi bi l i ty of the fl ui d, and the effi ci ency speci fi ed.
Use Pump to change pressure when the power requi rement i s needed or known.
For pressure change onl y, you can use other model s such as Heater.
Pump can model pumps and hydraul i c turbi nes.
Use the Pump bl ock to rate a pump or a turbi ne by speci fyi ng scal ar parameters
or by speci fyi ng the rel ated performance curves. To use the performance curves,
you can speci fy ei ther:
Di mensi onal curves such as head versus fl ow or power versus fl ow
Di mensi onl ess curves such as head coeffi ci ent versus fl ow coeffi ci ent
Flowsheet Connectivity for Pump
Work
(optional)
Material
Work (optional)
Water (optional)
Material
(any number)
Material Streams
Versi on 10
Chapter 6
Work Streams
Inlet Any number of work streams (opti onal )
Outlet One work stream for the net work l oad (opti onal )
I f you do not speci fy ei ther power or pressure on the Setup Speci fi cati ons sheet,
Pump uses the sum of the i nl et work streams as a power speci fi cati on.
Otherwi se, Pump uses the i nl et work stream(s) onl y to cal cul ate the net work
l oad. The net work l oad i s the sum of the i nl et work streams mi nus the actual
(cal cul ated) work l oad.
You can use an opti onal outl et work stream for the net work l oad.
Specifying Pump
Use the Setup Speci fi cati ons sheet for Pump speci fi cati ons.
If you specify Pump calculates
Discharge pressure Power required or produced
Pressure increase (for a pump) or decrease (for a turbine) Power required or produced
Pressure ratio (outlet pressure to inlet pressure) Power required or produced
Power required (for a pump) or produced (for a turbine) Discharge pressure
Curves of head, discharge pressure, pressure ratio,
pressure change, or head coefficient
Power required or produced
Power curve Discharge pressure
You can suppl y a Fortran subrouti ne to cal cul ate performance curves i n Pump.
See ASPEN PLUS User Models for more i nformati on.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Pump:
Setup Specify operating conditions, efficiencies, net positive suction head parameters,
specific speed parameters, valid phases, and flash convergence parameters
PerformanceCurves Specify parameters and enter data for the performance curves
UserSubroutines Specify name and parameters for the user performance curve subroutine
Results View summary of Pump results, material and energy balance results, and
performance curve summary
Versi on 10
Pressure
Changers
NPSH Available
The Net Posi ti ve Sucti on Head (NPSH) avai l abl e for a pump i s defi ned as:
NPSHA P P H H
in vapor v s
+ +
Where:
NPSHA = Net Posi ti ve Sucti on Head Avai l abl e
P
in
= I nl et pressure
P
vapor
= Vapor pressure of the l i qui d at i nl et condi ti ons
H
v
= Vel oci ty head
(=u g
2
2 / , u i s the vel oci ty and g i s gravi tati on constant)
H
s
= Hydraul i c stati c head corrected to the pump centerl i ne
The NPSH avai l abl e has to be greater than the NPSH requi red (NPSHR) to avoi d
cavi tati on. NPSH requi red i s a functi on of pump desi gn.
NPSH Required
The Net Posi ti ve Sucti on Head (NPSH) requi red can be consi dered the sucti on
pressure requi red by the pump for safe, rel i abl e operati on. The NPSHR can be
speci fi ed usi ng the performance curves on the PerformanceCurves NPSHR sheet,
or cal cul ated from the fol l owi ng empi ri cal equati on by speci fyi ng sucti on speci fi c
speed ( N
ss
) on the Setup Cal cul ati onOpti ons sheet.
NPSHR
N Q
N
ss
1
]
1
0 5
4
3
.
Where:
NPSHR = Net Posi ti ve Sucti on Head Requi red
N = Pump shaft speed (rpm)
Q = Vol umetri c fl ow rate at the sucti on condi ti ons
N
ss
= Sucti on speci fi c speed
Versi on 10
Chapter 6
The uni ts for Qand NPSHR are:
US: Q i n gal /mi n and NPSHR i n feet
Metri c: Q i n cum/hr and NPSHR i n meters
Specific Speed
Speci fi c speed and sucti on speci fi c speed are two i mportant parameters that
defi ne the sui tabi l i ty of a pump desi gn for i ts i ntended condi ti ons. The pump
speci fi c speed i s defi ned as:
N
N Q
Head
s
0 5
0 75
.
.
Where:
Head = Head devel oped across the pump
N
s
= Speci fi c speed
The uni ts for Qand Head are:
US: Head i n feet
Metri c: Head i n meters
Versi on 10
Pressure
Changers
I n general , pumps wi th a l ow speci fi c speed are termed l ow capaci ty and those
wi th a hi gh speci fi c speed are termed hi gh capaci ty. For a turbi ne, the speci fi c
speed i s defi ned as fol l ows:
N
N BHP
Head
s
0 5
1 25
.
.
Where:
N
s
= Speci fi c speed
BHP = Devel oped horsepower
Head = Total dynami c head across turbi ne
Suction Specific Speed
Sucti on speci fi c speed ( N
ss
) i s an i ndex number for a centri fugal pump and i s
used to defi ne i ts sucti on characteri sti c. I t i s defi ned as fol l ows:
N
N Q
NPSHR
ss
0 5
0 75
.
.
Where:
NPSHR = Net posi ti ve sucti on head requi red for a pump or net
posi ti ve di scharge head requi red for a turbi ne
N
ss
= Sucti on speci fi c speed
The uni ts for Q and NPSHR are:
US: Q i n gal /mi n and NPSHR i n feet
Metri c: Q i n cum/hr and NPSHR i n meters
Versi on 10
Chapter 6
Sucti on speci fi c speed i s a cri teri on of a pumps performance wi th regard to
cavi tati on. For a pump of normal desi gn, val ues of N
ss
vary from 6,000 to 12,000
i n US uni ts. A typi cal val ue i s 8,500.
Head Coefficient
Head coeffi ci ent i s defi ned as fol l ows:
Headc
Head g
u
2
Where:
Headc = Head coeffi ci ent
Head = Head devel oped across the pump
g
= Gravi tati onal constant
u = I mpel l er ti p speed
Flow Coefficient
Fl ow coeffi ci ent i s the rati o of di scharge throat vel oci ty to i mpel l er ti p speed. I t i s
defi ned as:
Flowc
Q
A u
1
A d
1 1
2
4 /
Where:
Flowc = Fl ow coeffi ci ent
Q = Vol umetri c fl ow rate
A
1
= Cross-secti onal area of di scharge throat
d
1
= Di ameter of di scharge throat
u = I mpel l er ti p speed
Versi on 10
Pressure
Changers
The di ameter of throat and di ameter of i mpel l er are rel ated by the fol l owi ng
empi ri cal equati on:
N
d
Diam
s
5500
1
Where:
N
s
= Speci fi c speed at the best effi ci ency poi nt
Diam = Di ameter of i mpel l er
You can speci fy Speci fi c Speed (N
s
) on the Setup Cal cul ati onOpti ons sheet.
Versi on 10
Chapter 6
Compr
Compressor/Turbine
Use Compr to model :
A pol ytropi c centri fugal compressor
A pol ytropi c posi ti ve di spl acement compressor
An i sentropi c compressor
An i sentropi c turbi ne
Use Compr to change stream pressure when energy-rel ated i nformati on, such as
power requi rement, i s needed or known.
Compr can handl e si ngl e-phase as wel l as two- and three-phase cal cul ati ons.
You can use Compr to rate a si ngl e stage of a compressor or a si ngl e wheel of a
compressor, by speci fyi ng the rel ated performance curves. Compr al l ows you to
speci fy ei ther:
Di mensi onal curves, such as head versus fl ow or power versus fl ow
Di mensi onl ess curves, such as head coeffi ci ent versus fl ow coeffi ci ent
Compr can al so cal cul ate compressor shaft speed.
Compr cannot handl e performance curves for a turbi ne.
Flowsheet Connectivity for Compr
Material
(any number)
Material
Water (optional)
Work
(optional)
Work (optional)
Material Streams
Versi on 10
Pressure
Changers
Work Streams
Outlet One work stream for net work l oad (opti onal )
I f you do not speci fy ei ther power or pressure on the Compr Setup Speci fi cati ons
sheet, Compr uses the sum of the i nl et work streams as a power speci fi cati on.
Otherwi se, Compr uses the i nl et work stream(s) onl y to cal cul ate the net work
l oad. The net work l oad i s the sum of the i nl et work streams mi nus the actual
(cal cul ated) work l oad.
You can use an opti onal outl et work stream for the net work l oad.
Specifying Compr
If you specify Compr calculates
Power required (for a compressor) or produced (for a turbine) Discharge pressure
Curves of head, power, discharge pressure, pressure ratio, pressure
change, or head coefficient
Power required and discharge pressure
Discharge pressure and curves of head or power or head coefficient Power required, discharge pressure, and shaft
speed
Power required and curves of discharge pressure, pressure ratio, or
pressure change
Discharge pressure, and shaft speed
When you use performance curves, you can speci fy ei ther a scal ar val ue of
effi ci ency or effi ci ency curves.
You can suppl y a Fortran subrouti ne to cal cul ate performance curves i n Compr.
See ASPEN PLUS User Models for more i nformati on.
Some requi red speci fi cati ons depend on the compressor type. Speci fy the
compressor type on the Setup Speci fi cati ons sheet.
You can model a pol ytropi c compressor usi ng ei ther the GPSA or ASME method.
You can model an i sentropi c compressor/turbi ne usi ng ei ther the GPSA, ASME,
or Mol l i er-based methods.
The GPSA method can be based on ei ther:
Sucti on condi ti ons
Average of sucti on and di scharge condi ti ons
Versi on 10
Chapter 6
The ASME method i s more ri gorous than the GPSA method for pol ytropi c or
i sentropi c compressor cal cul ati ons. The Mol l i er method i s the most ri gorous for
i sentropi c cal cul ati ons.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Compr:
Setup Identify compressor specifications, calculation options, convergence parameters,
and valid phases
Performance Curves Specify parameters and enter data for the performance curves
User Subroutine Enter performance curve subroutine parameters and name
Results View summary of Compr results, material and energy balance results, and
performance curve summary
Polytropic Efficiency
The pol ytropi c effi ci ency
p
i s used i n the equati on for the pol ytropi c
compressi on rati o:
n
n
k
k
p
_
,
1 1
The basi c compressor rel ati on i s:

h
P V
n
n
P
P
in in
p
out
in
n
n
_
,
_
,

1
]
1
1
1
1
1
1
Where:
n = Pol ytropi c coeffi ci ent
k = Heat capaci ty rati o Cp/Cv
p
= Pol ytropi c effi ci ency
h = Enthal py change per mol e
P = Pressure
V = Mol ar vol ume
Versi on 10
Pressure
Changers
Isentropic Efficiency
There are two equati ons for the i sentropi c effi ci ency
s
For compressi on:
s
out
s
in
out in
h h
h h
For expansi on:
s
out in
out
s
in
h h
h h
Where :
h = Mol ar enthal py
h
out
s
= Outl et mol ar enthal py assumi ng i sentropi c compressi on or
expansi on to the speci fi ed outl et pressure
Mechanical Efficiency
Mechani cal effi ci ency
m
i s used to cal cul ate the brake horsepower:
IHP F h
BHP IHP
m
/
Where:
I HP = I ndi cated horsepower
F = Mol e fl ow rate
BHP = Brake horsepower
m
= Mechani cal effi ci ency
Versi on 10
Chapter 6
MCompr
Multistage Compressor/Turbine
Use MCompr to model :
A mul ti -stage pol ytropi c compressor
A mul ti -stage pol ytropi c posi ti ve di spl acement compressor
A mul ti -stage i sentropi c compressor
A mul ti -stage i sentropi c turbi ne
For pol ytropi c compressors, MCompr can handl e a si ngl e, compressi bl e phase.
For speci al cases you can speci fy two- or three-phase cal cul ati ons. These
cal cul ati ons determi ne the outl et stream condi ti ons and the properti es used i n
the compressor equati ons. The accuracy of resul ts depends pri mari l y on the
rel ati ve amounts of the phases present and the effi ci ency speci fi ed. The ri gorous
pol ytropi c compressor uses real fl ui d properti es cal cul ated from the property
method you speci fy. I t does not assume i deal gas behavi or.
MCompr handl es si ngl e-phase i sentropi c compressors and turbi nes. MCompr can
al so handl e two- and three-phase mi xtures.
You can use MCompr to rate a mul ti -stage compressor, by usi ng ei ther:
Stage-by-stage di mensi onal performance curves, such as head versus fl ow or
power versus fl ow
Wheel -by-wheel di mensi onl ess performance curves, such as head coeffi ci ent
versus fl ow coeffi ci ent
MCompr can al so cal cul ate shaft speed.
MCompr cannot handl e performance curves for a turbi ne.
Flowsheet Connectivity for MCompr
Heat
(optional)
Work
(optional)
Work
(any number)
To
Stage
K + 1
From
Stage
K - 1
Feed to
Stage
K + 1
(any number)
Heat
(any number)
Water
(optional)
Knockout
Stage K
Cooler
Stage K
Compressor
Stage K
Versi on 10
Pressure
Changers
Material Streams
Inlet At l east one materi al stream for the fi rst compressor stage
One or more materi al streams for stages after the fi rst (opti onal ). These
streams enter the i ntercool er before the stages you speci fy.
Outlet One materi al stream l eavi ng the l ast compressor stage
Ei ther one opti onal knockout materi al stream for each i ntercool er for the
l i qui d formed, or one opti onal gl obal knockout for the l i qui d formed i n al l
i ntercool ers
Ei ther one opti onal water decant stream for each i ntercool er, or one
opti onal gl obal water decant stream
I f you use l i qui d knockout outl et streams from one stage, you must use them for
al l stages. The l ast stage cannot have a l i qui d knockout materi al stream or a
water decant stream.
Heat Streams
Inlet Any number of heat streams to each i ntercool er (opti onal )
Outlet Ei ther one opti onal heat stream for the net heat l oad of each i ntercool er,
or one gl obal heat outl et stream for the net heat duty for al l i ntercool ers
I f you do not speci fy cool er condi ti ons on the Setup Cool er sheet, MCompr adds
the heat streams together and uses the total as a duty speci fi cati on for the cool er.
The net heat l oad equal s the heat i n the i nl et heat streams mi nus the actual
(cal cul ated) heat duty.
I f you use a heat outl et from one stage, you must use one for al l stages.
Work Streams
Inlet Any number of work streams to each compressor stage (opti onal )
Outlet Ei ther one opti onal work stream for net work l oad, or one gl obal work
stream for the net power for al l compressor stages
MCompr adds al l work i nl et streams together to provi de the power requi rement.
I f you do not speci fy power or pressure on the Setup Specs sheet, MCompr uses
the total power as a power speci fi cati on for the stage.
The power i n the outl et work stream equal s the power i n the i nl et work streams
mi nus the actual (cal cul ated) power requi red.
I f you use a work outl et from one stage, you must use one for al l stages.
Versi on 10
Chapter 6
Specifying MCompr
If you specify MCompr calculates
Power required (for a compressor) or produced (for a turbine) Discharge pressure
Curves of head, power, discharge pressure, pressure ratio,
pressure change, or head coefficient
Power required and discharge pressure
Discharge pressure and curves of head or power or head
coefficient
Power required and shaft speed
When you use performance curves, you can speci fy ei ther a scal ar val ue for
effi ci ency or effi ci ency curves.
You can suppl y a Fortran subrouti ne to cal cul ate performance curves i n
MCompr. See ASPEN PLUS User Models for more i nformati on.
MCompr can have an i ntercool er between each compressi on (or expansi on) stage,
and an aftercool er after the l ast stage. You can perform one-, two-, or three-phase
fl ash cal cul ati ons i n the i ntercool ers. Each cool er can have a l i qui d knockout
stream, except the cool er after the l ast stage.
You can model a pol ytropi c compressor usi ng ei ther the GPSA
1
or ASME
2
method. You can model an i sentropi c compressor/turbi ne usi ng ei ther the GPSA,
ASME, or Mol l i er-based methods.
The GPSA method can be based on ei ther:
Sucti on condi ti ons
Average of sucti on and di scharge condi ti ons
The ASME method i s more ri gorous than the GPSA method for pol ytropi c or
i sentropi c compressor cal cul ati ons. The Mol l i er method i s the most ri gorous for
i sentropi c cal cul ati ons.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for MCompr:
Setup Identify multi-stage compressor specifications, stage specifications, cooler specifications,
convergence parameters, and valid phases
Performance Curves Specify parameters and enter data for the performance curves
User Subroutine Specify performance curve user subroutine parameters and name
continued
Versi on 10
Pressure
Changers
BlockOptions Override global values for physical properties, simulation options, diagnostic message levels, and report
options for this block
Results View summary of operating results, material and energy balance results, compressor and cooler profiles,
and performance profiles
Polytropic Efficiency
The pol ytropi c effi ci ency
p
i s used i n the equati on for the pol ytropi c compressi on
rati o:
n
n
k
k
p
_
,
1 1
The basi c compressor rel ati on i s:

h
P V
n
n
P
P
in in
p
out
in
n
n
_
,
_
,

1
]
1
1
1
1
1
1
Where:
n = Pol ytropi c coeffi ci ent
k = Heat capaci ty rati o Cp/Cv
p
= Pol ytropi c effi ci ency
P = Pressure
V = Mol ar vol ume
Isentropic Efficiency
There are two equati ons for the i sentropi c effi ci ency
s
For compressi on:
s
out
s
in
out in
h h
h h

Versi on 10
Chapter 6
For expansi on:
s
out in
out
s
in
h h
h h
Where :
h = Mol ar enthal py
h
out
s
= Outl et mol ar enthal py assumi ng i sentropi c compressi on or
expansi on to the speci fi ed outl et pressure
Mechanical Efficiency
Mechani cal effi ci ency
m
i s used to cal cul ate the brake horsepower:
IHP F h
BHP IHP
m
/
Where:
I HP = I ndi cated horsepower
F = Mol e fl ow rate
BHP = Brake horsepower
m
= Mechani cal effi ci ency
Parasitic Pressure Loss
The parasi ti c pressure l oss at the sucti on of a stage i s cal cul ated usi ng the
equati on:
P K
V

2
2
Where:
P = Parasi ti c pressure l oss
K = Vel oci ty head mul ti pl i er
= Densi ty
V = Li near vel oci ty of process gas at sucti on condi ti ons
Versi on 10
Pressure
Changers
Specific Speed
The speci fi c speed i s defi ned as:
SpSpd =
ShSpd (VflIn)
(Head)

0.5
0.75
Where:
ShSpd = Shaft speed
Vfl I n = Sucti on vol umetri c fl ow rate
Head = Head devel oped
Specific Diameter
The speci fi c di ameter i s defi ned as:
SpDiam =
ImpDiam (Head)
(VflIn)

0.25
0.5
Where:
I mpDi am = I mpel l er di ameter of compressor wheel
Vfl I n = Vol umetri c fl ow rate at sucti on condi ti ons
Head Coefficient
The head coeffi ci ent i s defi ned as:
Hc =
Head g
( ShSpd ImpDiam)

2
Where:
g = Gravi tati onal constant
= 3.1416
ShSpd = Shaft speed
Versi on 10
Chapter 6
Flow Coefficient
The fl ow coeffi ci ent i s defi ned as:
Fc
VflIn
ShSpd (ImpDiam
)
3
Where:
Vfl I n = Vol umetri c fl ow rate at sucti on condi ti ons
ShSpd = Shaft speed
References
1. GPSA Engineering Data Book, 1979, Chapter 4, pp. 5-6 to 5-10.
2. ASME Power Test Code 10, 1965, pp. 31-32.
Versi on 10
Pressure
Changers
Valve
Valve Pressure Drop
Val ve model s control val ves and pressure changers. Val ve rel ates the pressure
drop across a val ve to the val ve fl ow coeffi ci ent. Val ve assumes the fl ow i s
adi abati c, and determi nes the thermal and phase condi ti on of the stream at the
val ve outl et. Val ve can perform one-, two-, or three-phase cal cul ati ons.
Flowsheet Connectivity for Valve
Material Material
Material Streams
Inlet One materi al stream
Specifying Valve
Use the I nput Operati on sheet to sel ect the cal cul ati on type.
I f you sel ect the Pressure changer opti on or the Desi gn opti on for the cal cul ati on
type, you must speci fy, on the same sheet, one of the fol l owi ng:
Outl et pressure
Pressure drop
I f you sel ect the Pressure changer opti on, the speci fi cati on i s compl ete and Val ve
performs an adi abati c fl ash to cal cul ate the thermal and phase condi ti on of the
outl et stream.
I f you sel ect the Rati ng opti on for the cal cul ati on type, you must speci fy, on the
same sheet, one of the fol l owi ng:
Fl ow coeffi ci ent at operati ng val ve posi ti on
Val ve operati ng posi ti on (% Openi ng)
Versi on 10
Chapter 6
I f you speci fy the val ve operati ng posi ti on, you must al so speci fy one of the
fol l owi ng on the I nput Val veParameters sheet:
Characteri sti c equati on type and fl ow coeffi ci ent at maxi mum val ve openi ng
Data for fl ow coeffi ci ent (Cv) versus val ve openi ng i n the Val ve Parameters
Tabl e
A val ve from the bui l t-i n l i brary based on val ve type, manufacturer,
seri es/styl e, and si ze
On the I nput Cal cul ati onOpti ons sheet, you can speci fy that Val ve:
Check for choked fl ow
Cal cul ate cavi tati on i ndex
For vapor-contai ni ng streams, you must speci fy the pressure drop rati o factor
(Xt) for the val ve. For l i qui d-contai ni ng streams, i f you speci fy that Val ve check
for choked fl ow, you must al so speci fy the pressure recovery factor (Fl ) for the
val ve. You can speci fy the pressure drop rati o factor and the pressure recovery
factor for the val ve i n one of the fol l owi ng ways on the I nput Val veParameters
sheet:
Specify
Value at the operating valve position (Pres Drop Ratio Factor, Pres Recovery Factor)
Data for pressure drop ratio factor (Xt) and for pressure recovery factor (Fl) versus valve opening (% Opening) in the Valve
Parameters Table
A valve from the built-in library based on Valve Type, Manufacturer, Series/Style, and Size
I f you want to i ncl ude the effect of head l oss from pi pe fi tti ngs on the val ve fl ow
capaci ty, you must speci fy the di ameters of the val ve and pi pe fi tti ngs on the
I nput Pi peFi tti ngs sheet. Val ve uses the val ve and pi pe di ameters, and esti mates
the pi pi ng geometry factor to account for the reducti on i n fl ow capaci ty.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Val ve:
Input Specify valve operating conditions, flash convergence parameters, valid phases, valve
parameters, sizes for pipe fittings, calculation options, and Valve convergence parameters
Block Options Override global values for physical properties, simulation options, diagnostic message levels,
Results View summary of operating results and mass and energy balances
Versi on 10
Pressure
Changers
Pressure Drop Ratio Factor
The pressure drop rati o factor ( X
t
) accounts for the effect of the i nternal
geometry of the val ve on the change i n fl ui d densi ty as i t passes through the
val ve.
The pressure drop rati o factor i s the l i mi ti ng val ue (under choked condi ti ons) of
the pressure drop rati o and i s gi ven by:
X
F
dP
P
t
k
ch
in
_
,
1
(1)
Where:
dP
ch
= Pressure drop for choked vapor fl ow
F
k
= Rati o of speci fi c heats factor
P
in
= I nl et pressure
You can speci fy the pressure drop rati o factor on the I nput Val veParameters
sheet i n one of the fol l owi ng ways:
Choose a Li brary Val ve
Enter data for Xt and % Openi ng i n the Val ve Parameters Tabl e
Speci fy the val ue at the operati ng val ve posi ti on i n Val ve Factors
I f you know the rati o of the gas si zi ng coeffi ci ent ( ) C
g
to the l i qui d si zi ng
coeffi ci ent ( ) C
v
, as defi ned i n Fi sher Control s Company Control Valve Handbook,
you can cal cul ate the pressure drop rati o factor (wi th the assumpti on F
k
= 1) by
ei ther:
Usi ng val ve manufacturers data for
dP
P
ch
in
_
,
versus
C
C
g
v
i n equati on (1)
Usi ng the expressi on
X
F
C
C
t
k
g
v
_
,
6 31 10
4
2
.
Thi s rel ati onshi p i s based on equati ng the choked fl ow cal cul ated (i n US uni ts of
measure) wi th:
Uni versal Gas Si zi ng Equati on
W C rP
ch g in
106 .
I SA Standard Val ve Si zi ng Equati on
W N C Y F X rP
ch v k t in
6
Versi on 10
Chapter 6
Where:
W
ch
= Mass fl ow rate (choked fl ow)
r = Mass densi ty of i nl et stream
Y = Expansi on factor (= 0.667 for choked fl ow)
N
6
= Numeri cal constant (= 63.3 for US uni ts of measure)
I f you speci fy the pressure drop rati o factor by choosi ng a val ve from the bui l t-i n
l i brary or by enteri ng data i n the Val ve Parameters Tabl e on the I nput
Val veParameters sheet, Val ve uses cubi c spl i nes to i nterpol ate the val ue of the
pressure drop rati o factor at the operati ng val ve posi ti on.
Val ve uses the pressure drop rati o factor onl y when both of the fol l owi ng are
true:
Vapor i s present i n the i nl et stream
The Desi gn or Rati ng opti on i s sel ected for Cal cul ati on Type on the I nput
Operati on sheet
Pressure Recovery Factor
The pressure recovery factor ( ) F
l
accounts for the effect of the i nternal geometry
of the val ve on i ts l i qui d fl ow capaci ty under choked condi ti ons.
The pressure recovery factor i s defi ned as:
F
dP
P P
l
ch
in vc
1
]
1
1 2 /
Where:
dP
ch
= Pressure drop for choked l i qui d fl ow
P
in
= I nl et pressure
P
vc
= Pressure at the vena contracta i n the val ve
and
P
vc
= F P
f v
wi th
P
v
= Vapor pressure of i nl et l i qui d stream
F
f
= Li qui d cri ti cal pressure rati o factor
Versi on 10
Pressure
Changers
You can speci fy the pressure recovery factor on the I nput Val veParameters sheet
i n one of the fol l owi ng ways:
Choose a Li brary Val ve
Enter data for Fl and % Openi ng i n the Val ve Parameters Tabl e
Speci fy the val ue at the operati ng val ve posi ti on i n Val ve Factors
The pressure recovery factor i s equi val ent to the val ve recovery coeffi ci ent K
m
, as
defi ned i n Fi sher Control s Company Control Valve Handbook.
You can use the val ve recovery coeffi ci ent to cal cul ate the pressure recovery
factor as:
F K
l m
I f you speci fy the pressure recovery factor by choosi ng a val ve from the bui l t-i n
l i brary or by enteri ng tabul ar data i n the Val ve Parameters Tabl e on the I nput
Val veParameters sheet, Val ve uses cubi c spl i nes to i nterpol ate the val ue of the
pressure recovery factor at the operati ng val ve posi ti on.
The pressure recovery factor i s used i n the Val ve model cal cul ati ons onl y when
al l of the fol l owi ng are true:
Li qui d i s present i n the i nl et stream
The Check for Choked Fl ow box i s checked or the Set Equal to Choked Outl et
Pressure opti on i s sel ected on the I nput Cal cul ati onOpti ons sheet
The Desi gn or Rati ng opti on i s sel ected for Cal cul ati on Type on the I nput
Operati on sheet.
Valve Flow Coefficient
The val ve fl ow coeffi ci ent ( ) C
v
measures the fl ow capaci ty of the val ve. The fl ow
coeffi ci ent i s defi ned as the number of US gal l ons per mi nute of water (at 60F)
that wi l l pass through the val ve wi th a pressure drop of 1 psi .
The val ve fl ow coeffi ci ent rel ates the pressure drop across the val ve to the fl ow
rate as (I nstrument Soci ety of Ameri ca, 1985)
1
:
Li qui d
W N F C r P P
p v in out

6
( )
Gas/Vapor
W N F Y r P P
p in out

6
( )
wi th
Y
P P
F X P
in out
k t in

1
3
Versi on 10
Chapter 6
Where:
W = Mass fl ow rate
N
6
= Numeri cal constant (based on the uni ts of measure)
F
p
= Pi pi ng geometry factor
C
v
= Val ve fl ow coeffi ci ent
Y = Expansi on factor
P
in
= I nl et pressure
P
out
= Outl et pressure
r = Mass densi ty of i nl et stream
F
k
X
t
= Pressure drop rati o factor
You can speci fy the fl ow coeffi ci ent i n one of the fol l owi ng ways:
Use Fl ow Coef on the I nput Operati on sheet to speci fy the val ue at the
operati ng val ve posi ti on
Choose a Li brary Val ve on the I nput Val veParameters sheet
Enter data for Cv and % Openi ng i n the Val ve Parameters Tabl e on the I nput
Val veParameters sheet
Speci fy Val ve Characteri sti cs i n the I nput Val veParameters sheet
I f you speci fy the fl ow coeffi ci ent by choosi ng a val ve from the bui l t-i n l i brary or
by enteri ng data i n the Val ve Parameters Tabl e, Val ve uses cubi c spl i nes to
i nterpol ate the val ue of the fl ow coeffi ci ent at the operati ng val ve posi ti on.
Versi on 10
Pressure
Changers
Characteristic Equation Type
The characteri sti c equati on for the val ve rel ates the fl ow coeffi ci ent to the val ve
openi ng. Use the I nput Val veParameters sheet to speci fy the characteri sti c
equati on type. The si x bui l t-i n characteri sti c equati ons are:
Type Equation
Linear
V P
Parabolic
V P 0 01
2
.
Square Root
V P 100 .
Quick Opening
( )
V
P
P
10 0
10 9 9 10
3 2
.
. .
Equal Percentage
V
P
P
0 01
2 0 10 10
2
8 4
.
. .
Hyperbolic
( )
V
P
P
01
10 9 9 10
5 2
.
. .

Where:
P =Val ve openi ng as a percentage of maxi mum openi ng
V =Fl ow coeffi ci ent as a percentage of fl ow coeffi ci ent at maxi mum openi ng
Piping Geometry Factor
The pi pi ng geometry factor i s defi ned as:
F
C
C
p
p
Where:
C
p
= Fl ow coeffi ci ent of the val ve wi th attached fi tti ngs
C
= Fl ow coeffi ci ent of the val ve i nstal l ed i n a strai ght pi pe of the

same si ze
The pi pi ng geometry factor accounts for the reducti on i n the fl ow capaci ty of a
val ve due to the head l oss from the pi pe fi tti ngs. The pi pi ng geometry factor has
a defaul t val ue of 1.0 i f the val ve and pi pe fi tti ngs have the same di ameter.
Versi on 10
Chapter 6
ASPEN PLUS cal cul ates the pi pi ng geometry factor as (I nstrument Soci ety of
Ameri ca, 1985)
1
:
F
KC
N d
p
+
_
,
2
2
4
0 5
1
.
wi th K K K K K
B B
+ +
1 2 1 2
Where:
K
d
D
1
2
1
2
2
05 1
_
,
. , K
d
D
2
2
2
2
2
10 1
_
,
. , K
d
D
B1
1
4
1
_
,
, K
d
D
B2
2
4
1
_
,
and:
F
p
= Pi pi ng geometry factor
C
= Val ve fl ow coeffi ci ent

N
2
= Numeri cal constant (based on the uni ts of measure)
d = Val ve di ameter
K K
1 2
, = Resi stance coeffi ci ents of the i nl et and outl et fi tti ngs
K K
B B 1 2
, = Bernoul l i coeffi ci ents for the i nl et and outl et fi tti ngs
D
1
= I nl et pi pe di ameter
D
2
= Outl et pi pe di ameter
I f the val ve and pi pe fi tti ngs di ameters are di fferent and you wi sh to i ncl ude the
effect of the addi ti onal head l oss on the val ve fl ow capaci ty, you must speci fy the
val ve and pi pe di ameters on the I nput Pi peFi tti ngs sheet.
Versi on 10
Pressure
Changers
Choked Flow
ASPEN PLUS cal cul ates the l i mi ti ng pressure drop for choked fl ow condi ti ons
usi ng (I nstrument Soci ety of Ameri ca, 1985)
1
:
Li qui d
( )
dP F P F P
lc
L
in f

2
Vapor dP F X P
c k T in
wi th
F
P
P
f
v
c

_
,
0 96 0 28
0 5
. .
.
Where:
F
L
= Pressure recovery factor
F
f
= Li qui d cri ti cal pressure rati o factor
F
k
X
T
= Pressure drop rati o factor
P
in
= I nl et pressure
P
= Vapor pressure at i nl et
P
c
= Cri ti cal pressure at i nl et
dP
lc
= Li mi ti ng pressure drop, l i qui d phase
dP
vc
= Li mi ti ng pressure drop, vapor phase
For mul ti -phase streams, Val ve takes the l i mi ti ng pressure drop for choked fl ow
to be the smal l er of dP
lc
and dP
vc
. Fl ow i n the val ve i s choked when the pressure
drop exceeds thi s l i mi ti ng pressure drop. Val ve di spl ays the choki ng status of the
val ve i f you check the Check for Choki ng box on the I nput Cal cul ati onOpti ons
sheet.
Versi on 10
Chapter 6
Cavitation Index
The l i kel i hood of cavi tati on i n a val ve i s measured by the cavi tati on i ndex.
ASPEN PLUS cal cul ates the cavi tati on i ndex as (I nstrument Soci ety of Ameri ca,
1985)
1
:
K
P P
P P
c
in out
in v
_
,
Where:
K
c
= Cavi tati on i ndex
P
in
= I nl et pressure
P
out
= Outl et pressure
P
v
= Vapor pressure at i nl et
The cavi tati on i ndex defi ni ti on i s val i d onl y for al l -l i qui d streams. Val ve
cal cul ates the cavi tati on i ndex i f you check the Cal cul ate Cavi tati on I ndex box on
the I nput Cal cul ati onOpti ons sheet.
References
1. Fl ow Equati ons for Si zi ng Control Val ves, I SA-S75.01-1985, I nstrument
Soci ety of Ameri ca, 1985.
Versi on 10
Pressure
Changers
Pipe
Pipe Pressure Drop
Pi pe cal cul ates the pressure drop and heat transfer i n a si ngl e segment pi pe. You
can al so use Pi pe to model the pressure drop due to fi tti ngs.
Pi pe handl es a si ngl e i nl et and outl et materi al stream. Pi pe assumes the fl ow i s
one-di mensi onal , steady-state, and ful l y devel oped (that i s, no entrance effects
are model ed). Pi pe can perform one-, two-, or three-phase cal cul ati ons. Fl ow
di recti on and el evati on angl e are arbi trary.
To model mul ti pl e pi pe segments of di fferent di ameters or el evati ons, use
Pi pel i ne i nstead of Pi pe.
I f the i nl et pressure i s known, Pi pe cal cul ates the outl et pressure. I f the outl et
pressure i s known, Pi pe cal cul ates the i nl et pressure and updates the state
vari abl es of the i nl et stream.
Use Pi pe to:
Cal cul ate i nl et or di scharge condi ti ons
Cal cul ate pressure drops for one-, two-, or three-phase vapor and l i qui d fl ows
Flowsheet Connectivity for Pipe
Material
Material
Material Streams
Versi on 10
Chapter 6
Specifying Pipe
You must speci fy the fol l owi ng for Pi pe:
Pi pe l ength, di ameter, roughness, and angl e on the Setup Pi peParameters
sheet
Thermal speci fi cati on type on the Setup Thermal Speci fi cati on sheet to
determi ne whether Pi pe operates wi th a temperature profi l e or temperature
i s cal cul ated
Whether to i ntegrate, assume constant dP/dL, or use a cl osed form equati on
on the Advanced Methods sheet
Fri cti onal and hol dup correl ati on when a cl osed form equati on i s not used on
the Advanced Methods sheet
Pressure and temperature gri d for fl ui d property cal cul ati ons on the
Advanced PropertyGri d sheet, i f you request a pressure-temperature gri d on
the AdvancedCal cul ati on Opti ons sheet
I ntegrati on di recti on i n whi ch cal cul ati ons proceed wi th respect to fl ow on the
Advanced Cal cul ati onOpti ons sheet
If the option selected is Pipe needs the And the integration direction is
Calculate pipe outlet
pressure (default)
Inlet pressure Downstream
Calculate pipe inlet pressure Outlet pressure Upstream
Pi pe uses the i nl et or outl et stream pressure to start the cal cul ati ons. I f the
stream i s an external feed to your fl owsheet, or the outl et of a bl ock that wi l l
execute after Pi pe, use the Stream Speci fi cati ons sheet to speci fy the stream
pressure. I f the i ntegrati on di recti on i s upstream, you can al so speci fy the i ni ti al
pressure for Pi pe on the Advanced Cal cul ati onOpti ons sheet, by enteri ng the
outl et pressure. Thi s pressure val ue wi l l overri de the stream pressure entered on
the Stream Speci fi cati ons sheet.
Sel ect the fl ow cal cul ati on opti on on the Advanced Cal cul ati onOpti ons sheet to
speci fy whether Pi pe i s to cal cul ate the outl et or i nl et stream fl ow and
composi ti on.
If the option selected is Pipe needs the
Reference inlet stream
(default)
Inlet flow and composition
Use outlet stream flow Outlet flow and composition
Versi on 10
Pressure
Changers
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Pi pe:
Setup Specify pipe parameters, thermal specifications, fittings, flash convergence
parameters and property profiles to be reported
Advanced Specify calculation options, solution methods, property grid, integration
parameters and Beggs and Brill coefficients
UserSubroutine Specify pressure drop and/or holdup user subroutine name and parameters
Results View summary of Pipe results, inlet and outlet stream results, material and
energy balance results, and profiles
Stream Specification
You must i ni ti al i ze the i nl et stream to Pi pe whenever the opti on to reference
i nl et stream i s sel ected, even i f the i nl et pressure i s bei ng cal cul ated. Si mi l arl y,
you must i ni ti al i ze the outl et stream whenever the opti on to use the outl et
stream fl ow i s sel ected. The i ni ti al i zed stream must be one of the fol l owi ng:
Entered on a Stream Speci fi cati ons sheet
An outl et stream from part of the fl owsheet executed (i f opti on to use outl et
stream fl ow i s sel ected)
Transferred from another part of a fl owsheet usi ng a Transfer bl ock
Physical Property Calculations
You can speci fy that a ri gorous fl ash i s to be performed each ti me properti es are
cal cul ated, by sel ecti ng the opti on to do Fl ash at Each I ntegrati on Step on the
Advanced Cal cul ati onOpti ons sheet. I f you sel ect the opti on to I nterpol ate from
Property Gri d, Pi pe wi l l determi ne properti es by i nterpol ati ng i n a tabl e of
property val ues at vari ous temperatures and pressures. Speci fy one of the
fol l owi ng i f you use the Property Gri d:
A range of temperatures and pressures on the Advanced Property Gri d sheet.
Pi pe wi l l cal cul ate properti es at these condi ti ons and i nterpol ate
The bl ock I D of a Pi pe bl ock for whi ch the opti on to i nterpol ate from property
gri d was al so sel ected, and whi ch wi l l be executed before the current bl ock i n
the fl owsheet
Versi on 10
Chapter 6
Pi pe can cal cul ate pressure drop for ei ther one-, two-, or three-phase vapor and
l i qui d fl ows. I f vapor-l i qui d fl ow exi sts, Pi pe al so cal cul ates l i qui d hol dup and
fl ow regi me (pattern). You may speci fy a fl owi ng fl ui d temperature profi l e, or
Pi pe can determi ne i t from heat transfer cal cul ati ons. Pi pe treats mul ti pl e l i qui d
phases (for exampl e, oi l and water) as a si ngl e homogeneous l i qui d phase for
pressure-drop and hol dup cal cul ati ons. Pi pe automati cal l y detects the speci al
case of a si ngl e component fl ui d (for exampl e, steam) and treats i t appropri atel y.
Downstream and Upstream Integration
For downstream and upstream i ntegrati on, the combi nati on of opti ons sel ected
for pressure and fl ow cal cul ati on on the Advanced Cal cul ati onOpti ons sheet
determi ne whi ch stream Pi pe wi l l update. The fol l owi ng tabl e descri bes the
avai l abl e combi nati ons. The next fi gure, Downstream and Upstream I ntegrati on,
defi nes the i nl et and outl et stream and pressure vari abl es:
If the pressure calculation option is And the flow calculation option is Then Pipe updates the
Calculate pipe outlet pressure Reference inlet stream Outlet stream only
Calculate pipe outlet pressure Use outlet stream flow Outlet stream thermodynamic conditions
Inlet stream composition and flow
Calculate pipe inlet pressure Use outlet stream flow Inlet stream only
Calculate pipe inlet pressure Reference inlet stream Inlet stream thermodynamic conditions
Outlet stream composition and flow
Inlet Stream
Inlet Pressure Outlet Pressure
Outlet Stream
Versi on 10
Pressure
Changers
Design-Spec Convergence Loop
Use cauti on when usi ng Pi pe i nsi de a Desi gn-Spec convergence l oop. For
exampl e, you can mani pul ate the fl ow rate to a pi pe to achi eve a desi red pi pe
outl et pressure. Duri ng the desi gn speci fi cati on convergence, the fl ow rate
vari abl es may become unreasonabl e i n an i ntermedi ate i terati on, causi ng Pi pe to
predi ct a negati ve pressure. Convergence di ffi cul ti es occur as a resul t. You can
avoi d thi s si tuati on by doi ng one of the fol l owi ng:
Keep the upper l i mi t of the fl ow rate suffi ci entl y l ow i n Desi gn-Spec
Perform an upstream i ntegrati on from the known outl et pressure. Sel ect
opti on to cal cul ate pi pe i nl et pressure on the Advanced Cal cul ati onOpti ons
sheet for thi s purpose. Defi ne a Desi gn-Spec to mani pul ate the fl ow rate to
achi eve the speci fi ed i nl et pressure.
Erosional Velocity
Erosi onal vel oci ty i s the vel oci ty of the fl ui d i n the pi pe, above whi ch the pi pe
materi al wi l l start to break off. The fl ui d i s travel i ng so fast that i t starts to stri p
materi al from the wal l s of the pi pe. I n general use, the fl ow rate shoul d be bel ow
thi s val ue.
You can speci fy the erosi onal vel oci ty coeffi ci ent on the Setup Pi pe Parameters
sheet.
The erosi onal vel oci ty i s rel ated to the erosi onal vel oci ty coeffi ci ent by the
fol l owi ng equati on:
c
c
Where:
c
= Erosi onal vel oci ty i n ft/second
c = Erosi onal vel oci ty coeffi ci ent (defaul t=100)
= Densi ty i n l bs/cubi c ft
Methane Gas Systems
Gas systems consi sti ng mostl y of methane occur frequentl y i n the dense-phase
regi on of wel l bores and fl owl i nes. I n the dense-phase regi on, defi nabl e vapor and
l i qui d phases do not exi st. Equati on-of-state methods cl assi fy the dense-phase
materi al as ei ther al l vapor or al l l i qui d. Si gni fi cant di fferences i n the predi cted
fl ui d transport properti es may occur, dependi ng on whether you choose the vapor
or l i qui d state.
Versi on 10
Chapter 6
Experi ence has shown that gas system fl ow i n the dense-phase regi on i s best
model ed by usi ng vapor-phase properti es. For systems consi sti ng of mostl y
methane, where the pi pe condi ti ons l i e above the cri condenbar of the phase
envel ope, speci fy vapor-onl y val i d phase on the Setup Fl ashOpti ons sheet.
Modeling Valves and Fittings
Pi pe assumes that the pressure drop due to val ves and fi tti ngs i s di stri buted
evenl y al ong the speci fi ed l ength of the pi pe. The total l ength Pi pe uses i n
cal cul ati ons corresponds to the speci fi ed pi pe l ength, pl us any equi val ent pi pe
l ength due to val ves, fi tti ngs, and mi scel l aneous L/D.
I f the pi pe i s not hori zontal , Pi pe adjusts the angl e from the hori zontal to achi eve
the same verti cal ri se or fal l for the total l ength used i n the cal cul ati ons. Thi s
adjustment ensures the correct pressure drop due to el evati on.
I f the order and posi ti on of the val ves and fi tti ngs are i mportant, you need to
model each val ve and fi tti ng separatel y wi th a Pi pe model , speci fyi ng zero l ength
of pi pe.
Two-Phase Correlations
The fol l owi ng tabl es l i st the two-phase fri cti onal pressure drop and hol dup
correl ati ons avai l abl e.
Two-Phase Friction Factor Correlations
Pipe orientation Inclination Friction factor correlations
Horizontal -2 deg to +2 deg Beggs and Brill (BEGGS-BRILL)
Dukler (DUKLER)
Lockhart-Martinelli (LOCK-MART)
User subroutine (USER-SUBR)
Vertical +45 deg to +90 deg Beggs and Brill (BEGGS-BRILL)
Orkiszewski (ORK)
Angel-Welchon-Ros (AWR)
Hagedorn-Brown (H-BROWN)
User subroutine
(USER-SUBR)
Downhill -2 deg to -90 deg Beggs and Brill (BEGGS-BRILL)
Slack (SLACK)
Darcy (DARCY)
User subroutine
(USER-SUBR)
See ASPEN PLUS User Model s.

continued
Versi on 10
Pressure
Changers
Inclined +2 deg to +45 deg Beggs and Brill (BEGGS-BRILL)
Dukler (DUKLER)
Orkiszewski (ORKI)
Darcy (DARCY)
User subroutine
(USER-SUBR)

Two-Phase Liquid Holdup Correlations
Pipe orientation Inclination Liquid holdup correlations
Eaton (EATON)
Hoogendorn (HOOG)
Hughmark (HUGH)
User subroutine
(USER-SUBR)
Orkiszewski(ORKI)
User subroutine
(USER-SUBR)
Slack (SLACK)
User subroutine
(USER-SUBR)
Flanigan (FLANIGAN)
Orkiszewski (ORKI)
User subroutine
(USER-SUBR)

Note Some of the rel ated i nformati on for the two-phase fri cti on factor
and l i qui d hol dup correl ati ons was taken from "Two-Phase Fl ow
i n Pi pes" by James P. Bri l l and H. Dal e Beggs, Si xth Edi ti on,
Thi rd Pri nti ng, January, 1991.
Versi on 10
Chapter 6
Beggs and Brill Correlation
The Beggs and Bri l l correl ati on
1
consi ders sl i p and fl ow regi mes are consi dered
wi th thi s method. Fri cti on factor and hol dup correl ati ons depend on fl ow regi me
and pi pe i ncl i nati on. I t i s sui tabl e for al l i ncl i nati ons, i ncl udi ng verti cal fl ow
downward.
Dukler Correlation
The Hughmark hol dup method shoul d be used wi th thi s pressure drop method.
The Dukl er method
2
was devel oped from fi el d data usi ng ai r-water mi xtures i n
1-i nch pi pes. I t tends to overpredi ct fri cti onal pressure drop. I t i s recommended
i n a desi gn manual publ i shed joi ntl y by the AGA and API .
Hagedorn-Brown Correlation
The Hagedorn-Brown correl ati on
3
consi ders sl i p between phases, but fl ow regi me
i s not consi dered. I t uses the same correl ati ons for l i qui d hol dup and fri cti on
factor for al l fl ow regi mes. I t i s an ol d method whi ch works wel l for conventi onal
oi l wel l s. I t i s sui tabl e for verti cal upward fl ow, but not downward. I t i s general l y
recommended for gas wel l s, and i s based on data obtai ned from U.S. Gul f Coast
oi l wel l s wi th 2-3/8 i nch and 2-7/8 i nch tubi ng.
Lockhart-Martinelli Correlation
The Lockhart-Marti nel l i correl ati on
4
i s one of the ol dest pressure drop
correl ati ons. I t does not consi der pressure drop due to accel erati on. The method
treats the vapor and l i qui d phases separatel y and uses a correcti on factor to fi nd
the 2-phase pressure gradi ent. Our i mpl ementati on assumes turbul ent gas and
l i qui d phase fl ow.
Orkiszewski Correlation
Sl i p and fl ow regi mes are consi dered i n the Orki szewski correl ati on
5
. The fri cti on
factor and hol dup correl ati on depend on the fl ow regi me. I t i s sui tabl e for verti cal
fl ow upward, but not downward. I t i s general l y rel i abl e for oi l wel l s. I t may
exhi bi t probl ems for oi l wel l s wi th hi gh water cuts or hi gh total gas to l i qui d
rati os. I t can si gni fi cantl y underpredi ct pressure drop for hi gher rate and hi gher
pressure wel l s (Beggs and Bri l l /1984)
3
.
Versi on 10
Pressure
Changers
Angel-Welchon-Ros Correlation
The Angel -Wel chon-Ros correl ati on method
6, 7
was devel oped for l ow gas-to-l i qui d
rati o water wel l s. I t assumes no sl i p between the vapor and l i qui d phases when
cal cul ati ng l i qui d hol dup.
Slack Correlation
The Sl ack correl ati on method assumes a strati fi ed fl ow regi me, and shoul d be
used onl y for downhi l l fl ow.
Eaton Correlation
The Eaton correl ati on
8
hol dup method was devel oped from data on 2- and 4-i nch
pi pes wi th a gas-water-crude mi xture, and a 17-i nch pi pe wi th a gas-oi l mi xture.
I t i s often used wi th the Dukl er fri cti onal pressure drop correl ati on.
Flanigan Correlation
The Fl ani gan correl ati on
9
hol dup methodwas devel oped from data taken i n a
16-i nch pi pe. I t cal cul ates l i qui d hol dup as a functi on of superfi ci al gas vel oci ty.
I t i s sui tabl e for i ncl i ned fl ow.
Beggs and Brill Correlation Parameters
The fol l owi ng tabl e l i sts the Beggs and Bri l l l i qui d hol dup correl ati on
parameters.
Flow Regime Name Description
Segregated BB1
BB2
BB3
Leading coefficient, A (default = 0.98)
Liquid volume fraction exponent, alpha (default = 0.4846)
Froude no. exp., beta (default = 0.0868)
Intermittent BB4
BB5
BB6
Distributed BB7
BB8
BB9
I n addi ti on, you can change the Beggs and Bri l l two-phase Fri cti on Factor modi fi er,
BB10 (defaul t = 1.0).
Versi on 10
Chapter 6
Closed-Form Methods
The fol l owi ng are cl osed-form methods:
Smi th
Weymouth
AGA
Ol i phant
Panhandl e A
Panhandl e B
Hazen-Wi l l i ams
Smith
The Smi th method
10
may be used for verti cal dry gas fl ow. I t shoul d be consi dered
for gas wel l s wi th condensate-gas rati os l ess than 50 bbl s/mcf, water-gas rati os
l ess than 3.5 bbl s/mcf, and fl ow rates above the Turner predi cted cri ti cal rate.
Smi th does not model gas wel l l oadup, and wi l l si gni fi cantl y under predi ct
wel l bore pressure drop i f l oadup i s actual l y occurri ng. Smi th resul ts must be
cross-checked agai nst the Turner predi cted cri ti cal rates to veri fy that the wel l i s
unl oaded. Smi th al so does not model condensati on of water vapor i n the wel l bore.
Weymouth
The Weymouth hori zontal gas fl ow equati on
11
was fi rst publ i shed i n 1912. I t i s
based on data taken on pi pes wi th di ameters from 0.8 i nches to 11.8 i nches. As a
resul t, i t i s most accurate for smal l er pi pes havi ng a di ameter l ess than 12
i nches.
AGA
The AGA method
12
may be used for hori zontal gas appl i cati ons.
Oliphant
The Ol i phant method
13
may be used for hori zontal gas appl i cati ons wi th
pressures between vacuum and 100 PSI .
Versi on 10
Pressure
Changers
Panhandle A
The Panhandl e A method
14
was devel oped by Panhandl e Eastern for hori zontal
gas fl ow i n l arge di ameter cross country gas transmi ssi on l i nes. As a resul t, i t i s
best used on l i nes havi ng di ameters l arger than 12 i nches. However, i t does not
account for gas compressi bi l i ty (Z-factor), and assumes compl etel y turbul ent
fl ow.
Panhandle B
The Panhandl e B method
14
i s a revi sed versi on of the Panhandl e A method for
hori zontal gas fl ow and was devel oped by Panhandl e Eastern.

I t i s al so cal l ed the
"Panhandl e Eastern Revi sed Equati on". I t accounts for the gas compressi bi l i ty
factor, and has revi sed exponents. Thi s equati on i s not qui te so Reynol ds-Number
dependent as the Panhandl e A equati on, al though i t, too, i s best for pi pe
di ameters of 12 i nches or more.
Hazen-Williams
The Hazen-Wi l l i ams method
14
was devel oped for the hori zontal fl ow of water.
When thi s method i s used, the Hazen-Wi l l i ams Coeffi ci ent must be speci fi ed i n
pl ace of the Segment Effi ci ency on the Connecti vi ty Edi t di al og box.
References
1. Beggs, H.D. and Bri l l , J.P., "A Study of Two-Phase Fl ow i n I ncl i ned Pi pes,"
J ournal of Petroleum Technology, May 1973, pp. 607-617.
2. Dukl er, A.E., Wi cks, M., and Cl evel and, R.G, "Fri cti onal Pressure Drop i n
Two-Phase Fl ow: An Approach Through Si mi l ari ty Anal ysi s," AI ChE J ournal,
Vol . 10, No. 1, January 1964, pp. 44-51.
3. Beggs, H.D. and Bri l l , J.P., "Two-Phase Fl ow i n Pi pes," Uni versi ty of Tul sa
Short Course Notes, Thi rd Pri nti ng, February 1984.
4. Lockhart, R.W. and Marti nel l i , R.C., "Proposed Correl ati on of Data for
I sothermal Two-Phase, Two-Component Fl ow i n Pi pes," Chemical
Engineering Progress, Vol . 45, 1949, pp. 39-48.
5. Orki szewski , J., "Predi cti ng Two-Phase Pressure Drops i n Verti cal Pi pe,"
J ournal of Petroleum Technology, June 1967, pp. 829-838.
Versi on 10
Chapter 6
6. Angel , R.R., and Wel chon, J.K., "Low-Rati o Gas-Li ft Correl ati on for Casi ng-
Tubi ng Annul i and Large Di ameter Tubi ng," API Drilling and Production
Practice, 1964, pp. 100-114.
7. Ros, N.C.J., "Si mul taneous Fl ow of Gas and Li qui d as Encountered i n Wel l
Tubi ng," J ournal of Petroleum Technology, October 1961, pp. 1037-1049.
8. Eaton, B.A. et al ., "The Predi cti on of Fl ow Patterns, Li qui d Hol dup, and
Pressure Losses Occurri ng Duri ng Conti nuous Two-Phase Fl ow i n Hori zontal
Pi pel i nes," Trans. AI ME, June 1967, pp. 815-828.
9. Fl ani gan, Ori n, "Effect of Uphi l l Fl ow on Pressure Drop i n Desi gn of Two-
Phase Gatheri ng Systems," Oil and Gas J ournal , March 10, 1958, pp. 132-
141.
10. Smi th, R. V., "Determi ni ng Fri cti on Factors for Measuri ng Producti vi ty of
Gas Wel l s," AI ME Petroleum Transactions, Vol ume 189, 1950, pp. 73-82.
11. Weymouth, T.R., Transactions of the American Society of Mechanical
Engineers, Vol . 34, 1912.
12. "Steady Fl ow i n Gas Pi pes," Ameri can Gas Associ ati on, I GT Techni cal Report
10, Chi cago, 1965.
13. Ol i phant, F.N., "Producti on of Natural Gas," Report of USGS, 1902.
14. Engineering Data Book, Vol ume I I , Gas Processors Suppl i ers Associ ati on,
Tul sa, Okl ahoma, Revi sed Tenth Edi ti on, 1994.
Versi on 10
Pressure
Changers
Pipeline
Pipe Pressure Drop
Use Pi pel i ne to cal cul ate the pressure drop i n a strai ght pi pe or annul ar space.
Pi pel i ne can:
Si mul ate a pi pi ng network wi th successi ve bl ocks, i ncl udi ng wel l bores and
fl owl i nes
Contai n any number of segments wi thi n each bl ock to descri be pi pe geometry
Cal cul ate i nl et or di scharge condi ti ons
Cal cul ate pressure drops for one-, two-, or three-phase vapor and l i qui d fl ows.
Pi pel i ne treats mul ti pl e l i qui d phases (for exampl e, oi l and water) as a si ngl e
homogeneous l i qui d phase for pressure-drop and hol dup cal cul ati ons. I f
vapor-l i qui d fl ow exi sts, Pi pel i ne cal cul ates l i qui d hol dup and fl ow regi me
(pattern).
You may speci fy a fl owi ng fl ui d temperature profi l e, or Pi pel i ne can cal cul ate i t
from heat transfer cal cul ati ons. Fl ow i s assumed to be one-di mensi onal , steady-
state, and ful l y devel oped (no entrance effects are model ed). Fl ow di recti on and
el evati on angl e are arbi trary. To model a si ngl e pi pe segment wi th constant
di ameter and el evati on, you can al so use Pi pe.
Flowsheet Connectivity for Pipeline
Material
Material
Pipeline Streams
Material Streams
Versi on 10
Chapter 6
Specifying Pipeline
Use the Cal cul ati on Di recti on opti on on the Setup Confi gurati on sheet to speci fy
whether Pi pel i ne i s to cal cul ate the outl et or i nl et pressure.
If Calculation Direction = Pipeline will need the And the integration direction is
Calculate outlet pressure
(default)
Inlet pressure Downstream
Calculate inlet pressure Outlet pressure Upstream
Pi pel i ne uses the i nl et or outl et stream pressure to start the cal cul ati ons. I f the
stream i s an external feed to your fl owsheet, or the outl et of a bl ock that wi l l
execute after Pi pel i ne, use the Streams Speci fi cati ons sheet to speci fy the stream
pressure. You can al so speci fy the i ni ti al pressure for Pi pel i ne on the Setup
Confi gurati on sheet by enteri ng the pressure val ue at the i nl et or outl et. Thi s
pressure val ue overri des the stream pressure.
Use the Pi pel i ne fl ow basi s opti on on the Setup Confi gurati on sheet to speci fy
whether Pi pel i ne i s to cal cul ate the outl et or i nl et stream fl ow and composi ti on.
If Pipeline flow basis= Pipeline will need the
Use inlet stream flow
(default)
Inlet flow and composition
Reference outlet stream
flow
Outlet flow and composition
Use Thermal Opti ons on the Setup Confi gurati on sheet to speci fy whether or not
the node temperatures are to be cal cul ated by Pi pel i ne usi ng an energy bal ance.
When you sel ect the Speci fy Temperature Profi l e opti on, the temperature at each
node can be speci fi ed. When you choose the Constant Temperature opti on, the
temperature wi l l be same at every node. You can defi ne thi s temperature by
speci fyi ng the i nl et temperature (for downstream i ntegrati ons) or the outl et
temperature (for upstream i ntegrati ons). I f nei ther the i nl et nor the outl et
temperatures are speci fi ed, the temperature of the referenced stream wi l l be
used. When you choose the l i near temperature profi l e opti on, you can speci fy the
temperature at one or more nodes. Pi pel i ne wi l l do a l i near i nterpol ati on between
the temperatures speci fi ed to cal cul ate the fl ui d temperature i n each segment.
Versi on 10
Pressure
Changers
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Pi pel i ne:
Setup Specify pipeline configuration, segment connectivity and characteristics, calculation methods,
property grid parameters, flash convergence parameters, valid phases, and block-specific
diagnostic message level
Convergence Override default values for integration parameters, downhill flow options, correlation
parameters and Beggs and Brill coefficients (optional input)
UserSubroutines Specify name and parameters for pressure drop and liquid holdup user subroutines
Results View summary of Pipeline results, inlet and outlet stream results, profiles, and material and
energy balance results
Stream Specification
You must i ni ti al i ze the i nl et stream to Pi pel i ne whenever the Use I nl et Fl ow opti on
i s sel ected for Pi pel i ne Fl ow Basi s, even i f the i nl et pressure i s bei ng cal cul ated.
Si mi l arl y, you must i ni ti al i ze the outl et stream whenever you sel ect the Reference
Outl et Stream Fl ow opti on. The i ni ti al i zed stream must be one of the fol l owi ng:
On a stream form
An outl et stream from part of the fl owsheet executed previ ousl y
Transferred from another part of a fl owsheet usi ng a Transfer bl ock
Nodes and Segments
Create at l east one segment usi ng the New button on the Pi pel i ne Setup
Connecti vi ty sheet.
Enter speci fi cati ons for each segment on the Setup Connecti vi ty Segment Data
di al og box . For each segment, enter the i nl et and outl et node names (maxi mum 4
characters). The requi red data depends on the opti ons sel ected on the Setup
Confi gurati on sheet. I f you sel ect Do Energy Bal ance wi th Surroundi ngs, you
must speci fy a heat transfer coeffi ci ent (U-Val ue) and the ambi ent temperature.
I f you sel ect the Li near Temperature Profi l e opti on, Pi pel i ne uses the
temperatures speci fi ed for the nodes to overri de the stream val ues. I f speci fi cati ons
are not made for the nodes, then Pi pel i ne uses the stream val ues.
I f you sel ect Enter Node Coordi nate, you must enter node coordi nates (X, Y, and
El evati on) for each segment node. You must enter Length and Angl e for each
segment i f you sel ect Enter Segment Length and Angl e.
Versi on 10
Chapter 6
Physical Property Calculations
You can speci fy a ri gorous fl ash each ti me properti es are cal cul ated by sel ecti ng Do
Fl ash at Each Step on the Setup Confi gurati on sheet. I f I nterpol ate from Property
Gri d i s sel ected, Pi pel i ne wi l l determi ne properti es by i nterpol ati ng i n a tabl e of
property val ues at vari ous temperatures and pressures. Speci fy one of the fol l owi ng
i f you use the Property Gri d:
A range of temperatures and pressures gri d on the Setup PropertyGri d sheet.
Pi pel i ne cal cul ates properti es under these condi ti ons and i nterpol ates them.
The bl ock I D of a Pi pel i ne bl ock for whi ch you sel ected I nterpol ate from the
Property Gri d, and whi ch wi l l be executed before the current bl ock i n the
fl owsheet.
Pi pel i ne can cal cul ate pressure drop for ei ther one-, two-, or three-phase vapor and
l i qui d fl ows. I f vapor-l i qui d fl ow exi sts, Pi pel i ne al so cal cul ates l i qui d hol dup and
fl ow regi me (pattern). You may speci fy a fl owi ng fl ui d temperature profi l e, or
Pi pel i ne can cal cul ate i t from heat transfer cal cul ati ons. Pi pel i ne treats mul ti pl e
l i qui d phases (for exampl e, oi l and water) as a si ngl e homogeneous l i qui d phase for
pressure-drop and hol dup cal cul ati ons. Pi pel i ne automati cal l y detects the speci al
case of a si ngl e component fl ui d (for exampl e, steam) and treats i t appropri atel y.
For downstream and upstream i ntegrati on, the combi nati on of the sel ecti ons
made for Cal cul ati on Di recti on and Pi pel i ne Fl ow Basi s on the Setup
Confi gurati on sheet determi ne whi ch stream Pi pel i ne wi l l update. The fol l owi ng
tabl e descri bes the avai l abl e combi nati ons. The next fi gure, Downstream and
Upstream I ntegrati on, defi nes the i nl et and outl et stream and pressure
vari abl es.
If you specify Calculation
Direction= And Pipeline Flow Basis= Then Pipeline updates the
Calculate Outlet Pressure Reference inlet stream flow Outlet stream only
Calculate Outlet Pressure Use outlet stream flow Outlet stream thermodynamic conditions
Inlet stream composition and flow
Calculate Inlet Pressure Reference Outlet Stream Flow Inlet stream only
Calculate Inlet Pressure Use Inlet Stream Flow Inlet stream thermodynamic conditions
Outlet stream composition and flow
Versi on 10
Pressure
Changers
Inlet Stream
Inlet Pressure Outlet Pressure
Outlet Stream
Design Spec Convergence Loop
Use cauti on when usi ng Pi pel i ne i nsi de a Desi gn-Spec convergence l oop. For
exampl e, suppose you achi eve a desi red pi pel i ne outl et pressure by varyi ng the
fl ow rate to the pi pel i ne. I n thi s case, the fl ow rate vari abl e mi ght cause Pi pel i ne to
predi ct negati ve pressures, resul ti ng i n convergence probl ems. You can avoi d thi s
si tuati on by doi ng one of the fol l owi ng:
Keep the upper l i mi t of the fl ow rate suffi ci entl y l ow i n the Desi gn-Spec
Perform an upstream i ntegrati on from the known outl et pressure. Use
Cal cul ate I nl et Pressure on the Setup Confi gurati on sheet for thi s purpose.
Your Desi gn-Spec wi l l then need to mani pul ate the fl ow rate to achi eve the
speci fi ed i nl et pressure.
Erosional Velocity
Erosi onal vel oci ty i s the vel oci ty of the fl ui d i n the pi pe over whi ch the pi pe
materi al wi l l start to break off. The fl ui d i s travel i ng so fast that i t starts to stri p
materi al from the wal l s of the pi pe. I n general usage, the fl ow rate shoul d be bel ow
thi s val ue.
You can speci fy the erosi onal vel oci ty coeffi ci ent i n the C-Erosi on fi el d on the
Segment Data di al og box on the Setup Connecti vi ty sheet.
The erosi onal vel oci ty i s rel ated to the erosi onal vel oci ty coeffi ci ent by the
fol l owi ng equati on:
v
c
c
Where:
v
c
= Erosi onal vel oci ty i n ft/sec
c = Erosi onal vel oci ty coeffi ci ent (defaul t=100)
= Densi ty i n l b/cubi c ft
Versi on 10
Chapter 6
Methane Gas Systems
Gas systems consi sti ng mostl y of methane occur frequentl y i n the dense-phase
regi on of wel l bores and fl owl i nes. I n the dense-phase regi on, defi nabl e vapor and
l i qui d phases do not exi st. Equati on-of-state methods cl assi fy the dense-phase
materi al as ei ther al l vapor or al l l i qui d. Si gni fi cant di fferences i n the predi cted
fl ui d transport properti es may occur, dependi ng on whether you choose the vapor
or l i qui d state.
Experi ence has shown that gas system fl ow i n the dense-phase regi on i s best
model ed by usi ng vapor-phase properti es. For systems consi sti ng of mostl y
methane, where the pi pel i ne condi ti ons l i e above the cri condenbar of the phase
envel ope, speci fy Val i d Phases = Vapor onl y on the Setup Fl ashOpti ons sheet.
Two-Phase Correlations
The fol l owi ng tabl es l i st the two-phase fri cti onal pressure drop and hol dup
correl ati ons avai l abl e.
Two-Phase Friction Factor Correlations
Dukler (DUKLER)
Darcy (DARCY)
User subroutine
(USER-SUBR)
Orkiszewski (ORKI)
Darcy (DARCY)
User subroutine
(USER-SUBR)
Slack (SLACK)
Darcy (DARCY)
User subroutine
(USER-SUBR)
Dukler (DUKLER)
Orkiszewski (ORKI)
Darcy (DARCY)
User subroutine
(USER-SUBR)

Versi on 10
Pressure
Changers
Two-Phase Liquid Holdup Correlations
Pipe orientation Inclination Liquid holdup correlations
Eaton (EATON)
Hoogendorn (HOOG)
Hughmark (HUGH)
User subroutine
(USER-SUBR)
Orkiszewski (ORKI)
User subroutine
(USER-SUBR)
Slack (SLACK)
User subroutine
(USER-SUBR)
Flanigan (FLANIGAN)
Orkiszewski (ORKI)
User subroutine
(USER-SUBR)

Note Some of the rel ated i nformati on for the two-phase fri cti on factor
and l i qui d hol dup correl ati ons was taken from "Two-Phase Fl ow
i n Pi pes" by James P. Bri l l and H. Dal e Beggs, Si xth Edi ti on,
Thi rd Pri nti ng, January, 1991.
Beggs and Brill Correlation
Sl i p and fl ow regi mes are consi dered wi th thi s method. Fri cti on factor and
hol dup correl ati ons depend upon fl ow regi me and pi pe i ncl i nati on. I t i s sui tabl e
for al l i ncl i nati ons, i ncl udi ng verti cal fl ow downward.
1
Dukler Correlation
The Hughmark hol dup method shoul d be used wi th thi s pressure drop method.
The Dukl er method was devel oped from fi el d data usi ng ai r-water mi xtures i n
1-i nch pi pes.
2
I t tends to over-predi ct fri cti onal pressure drop. I t i s recommended
i n a desi gn manual publ i shed joi ntl y by the AGA and API .
Versi on 10
Chapter 6
Hagedorn-Brown Correlation
The Hagedorn-Brown correl ati on
3
consi ders sl i p between phases, but fl ow regi me
i s not consi dered. I t uses the same correl ati ons for l i qui d hol dup and fri cti on
factor for al l fl ow regi mes. I t i s an ol d method that works wel l for conventi onal oi l
wel l s. I t i s sui tabl e for verti cal upward fl ow, but not downward. I t i s general l y
recommended for gas wel l s, and i s based on data obtai ned from U.S. Gul f Coast
oi l wel l s wi th 2-3/8 i nch and 2-7/8 i nch tubi ng.
Lockhart-Martinelli Correlation
The Lockhart-Marti nel l i correl ati on
4
i s one of the ol dest pressure drop
correl ati ons. I t does not consi der pressure drop due to accel erati on. The method
treats the vapor and l i qui d phases separatel y and uses a correcti on factor to fi nd
the 2-phase pressure gradi ent. Our i mpl ementati on assumes turbul ent gas and
l i qui d phase fl ow.
Orkiszewski Correlation
The Orki szewsi correl ati on consi ders sl i p and fl ow regi mes
5
. The fri cti on factor
and hol dup correl ati on depend on the fl ow regi me. I t i s sui tabl e for verti cal fl ow
upward, but not downward. I t i s general l y rel i abl e for oi l wel l s. I t may exhi bi t
probl ems for oi l wel l s wi th hi gh water cuts or hi gh total gas to l i qui d rati os. I t
can si gni fi cantl y underpredi ct pressure drop for hi gher rate and hi gher pressure
wel l s (Beggs and Bri l l /1984)
3
.
Angel-Welchon-Ros Correlation
Thi s Angel -Wel chon-Ros method
6,7
was devel oped for l ow gas-to-l i qui d rati o water
wel l s. I t assumes no sl i p between the vapor and l i qui d phases when cal cul ati ng
l i qui d hol dup.
Slack Correlation
Thi s method assumes a strati fi ed fl ow regi me, and shoul d be used onl y for
downhi l l fl ow.
Eaton Correlation
The Eaton correl ati on
8
hol dup method was devel oped from data on 2- and 4-i nch
pi pes wi th a gas-water-crude mi xture, and a 17-i nch pi pe wi th a gas-oi l mi xture.
I t i s often used wi th the Dukl er fri cti onal pressure drop correl ati on.
Versi on 10
Pressure
Changers
Flanigan Correlation
The Fl ani gan correl ati on
9
hol dup method was devel oped from data taken i n a
16-i nch pi pe. I t cal cul ates l i qui d hol dup as a functi on of superfi ci al gas vel oci ty.
I t i s sui tabl e for i ncl i ned fl ow.
Beggs and Brill Correlation Parameters
The fol l owi ng tabl e l i sts the Beggs and Bri l l l i qui d hol dup correl ati on
parameters.
Flow Regime Name Description
Segregated BB1
BB2
BB3
Intermittent BB4
BB5
BB6
Distributed BB7
BB8
BB9
I n addi ti on, you can change the Beggs and Bri l l two-phase Fri cti on Factor modi fi er,
BB10 (defaul t = 1.0).
Closed-Form Methods
The fol l owi ng are cl osed-form methods:
Smi th
Weymouth
AGA
Ol i phant
Panhandl e A
Panhandl e B
Hazen-Wi l l i ams
Versi on 10
Chapter 6
Smith
The Smi th method
10
may be used for verti cal dry gas fl ow. I t shoul d be consi dered
for gas wel l s wi th condensate-gas rati os l ess than 50 bbl s/mcf, water-gas rati os
l ess than 3.5 bbl s/mcf, and fl ow rates above the Turner predi cted cri ti cal rate.
Smi th does not model gas wel l l oadup, and wi l l si gni fi cantl y underpredi ct
wel l bore pressure drop i f l oadup i s actual l y occurri ng. Smi th resul ts must be
cross-checked agai nst the Turner predi cted cri ti cal rates to veri fy that the wel l i s
unl oaded. Smi th al so does not model condensati on of water vapor i n the wel l bore.
Weymouth
The Weymouth
11
hori zontal gas fl ow equati on was fi rst publ i shed i n 1912. I t i s
based on data taken on pi pes wi th di ameters from 0.8 i nches to 11.8 i nches. As a
resul t, i t i s most accurate for smal l er pi pes havi ng a di ameter l ess than 12
i nches.
AGA
The AGA method
12
may be used for hori zontal gas appl i cati ons.
Oliphant
The Ol i phant method
13
may be used for hori zontal gas appl i cati ons wi th
pressures between vacuum and 100 PSI .
Panhandle A
The Panhandl e A method
14
was devel oped by Panhandl e Eastern for hori zontal
gas fl ow i n l arge di ameter cross country gas transmi ssi on l i nes. As a resul t, i t i s
best used on l i nes havi ng di ameters l arger than 12 i nches. However, i t does not
account for gas compressi bi l i ty (Z-factor), and assumes compl etel y turbul ent
fl ow.
Panhandle B
The Panhandl e B method
14
i s a revi sed versi on of the Panhandl e A method for
hori zontal gas fl ow and was devel oped by Panhandl e Eastern.

I t i s al so cal l ed the
"Panhandl e Eastern Revi sed Equati on". I t accounts for the gas compressi bi l i ty
factor, and has revi sed exponents. Thi s equati on i s not qui te so Reynol ds-Number
dependent as the Panhandl e A equati on, al though i t, too, i s best for pi pe
di ameters of 12 i nches or more.
Versi on 10
Pressure
Changers
Hazen-Williams
The Hazen-Wi l l i ams method
14
was devel oped for the hori zontal fl ow of water
When thi s method i s used, the Hazen-Wi l l i ams Coeffi ci ent must be speci fi ed i n
pl ace of the Segment Effi ci ency on the Connecti vi ty Edi t Di al og Box.
References
1. Beggs, H.D. and Bri l l , J.P., "A Study of Two-Phase Fl ow i n I ncl i ned Pi pes,"
J ournal of Petroleum Technology, May 1973, pp. 607-617.
2. Dukl er, A.E., Wi cks, M., and Cl evel and, R.G, "Fri cti onal Pressure Drop i n
Two-Phase Fl ow: An Approach Through Si mi l ari ty Anal ysi s," AI ChE J ournal,
Vol . 10, No. 1, January 1964, pp. 44-51.
3. Beggs, H.D. and Bri l l , J.P., "Two-Phase Fl ow i n Pi pes," Uni versi ty of Tul sa
Short Course Notes, Thi rd Pri nti ng, February 1984.
4. Lockhart, R.W. and Marti nel l i , R.C., "Proposed Correl ati on of Data for
I sothermal Two-Phase, Two-Component Fl ow i n Pi pes," Chemical
Engineering Progress, Vol . 45, 1949, pp. 39-48.
5. Orki szewski , J., "Predi cti ng Two-Phase Pressure Drops i n Verti cal Pi pe,"
J ournal of Petroleum Technology, June 1967, pp. 829-838.
6. Angel , R.R. and Wel chon, J.K., "Low-Rati o Gas-Li ft Correl ati on for Casi ng-
Tubi ng Annul i and Large Di ameter Tubi ng," API Dri l l i ng and Producti on
Practi ce, 1964, pp. 100-114.
7. Ros, N.C.J., "Si mul taneous Fl ow of Gas and Li qui d as Encountered i n Wel l
Tubi ng," J ournal of Petroleum Technology, October 1961, pp. 1037-1049.
8. Eaton, B.A. et al ., "The Predi cti on of Fl ow Patterns, Li qui d Hol dup, and
Pressure Losses Occurri ng Duri ng Conti nuous Two-Phase Fl ow i n Hori zontal
Pi pel i nes," Trans. AI ME, June 1967, pp. 815-828.
9. Fl ani gan, Ori n, "Effect of Uphi l l Fl ow on Pressure Drop i n Desi gn of Two-
Phase Gatheri ng Systems," Oil and Gas J ournal , March 10, 1958, pp. 132-
141.
10. Smi th, R. V., "Determi ni ng Fri cti on Factors for Measuri ng Producti vi ty of
Gas Wel l s," AI ME Petroleum Transactions, Vol ume 189, 1950, pp. 73-82.
11. Weymouth, T.R., Transactions of the American Society of Mechanical
Engineers, Vol . 34, 1912.
12. "Steady Fl ow i n Gas Pi pes," Ameri can Gas Associ ati on, I GT Techni cal Report
10, Chi cago, 1965.
Versi on 10
Chapter 6
13. Ol i phant, F.N., "Producti on of Natural Gas," Report of USGS, 1902.
14. Engi neeri ng Data Book, Vol ume I I , Gas Processors Suppl i ers Associ ati on,
Tul sa, Okl ahoma, Revi sed Tenth Edi ti on, 1994.
O O O O
Versi on 10
Pressure
Changers
Versi on 10
Chapter 7
7 Manipulators
Thi s chapter descri bes the model s for stream mani pul ators. The model s are:
Mult Stream multiplier Multiplies component and total flow rates by
a factor
Scaling streams by a factor
Dupl Stream duplicator Copies inlet stream into any number of
duplicate outlet streams
Duplicating feed or internal
streams
ClChng Stream class changer Changes stream class between blocks and
flowsheet sections
Adding or deleting empty
solid substreams between
flowsheet sections
Use stream mani pul ators to modi fy stream vari abl es for your conveni ence. They do
not represent real uni t operati ons.
Versi on 10
Manipulators
Mult
Stream Multiplier
Mul t mul ti pl i es the component fl ow rates and the total fl ow rate of a materi al
stream by a factor you suppl y on the Mul t I nput Speci fi cati ons sheet. For heat or
work streams, Mul t mul ti pl i es the heat or work fl ow. Sel ect the Heat (Q) and Work
(W) Mul t i cons from the Model Li brary for heat and work streams respecti vel y.
Mul t i s useful when other condi ti ons duri ng the si mul ati on determi ne the fl ow rate
of the stream. Mul t does not mai ntai n heat or materi al bal ances. For materi al
streams, the outl et stream has the same composi ti on and i ntensi ve properti es as
the i nl et stream.
Flowsheet Connectivity for Mult
Material
or
Heat
or
Work
Material
or
Heat
or
Work
Material Streams
Heat Streams
Inlet One heat stream
Outlet One heat stream
Work Streams
Inlet One work stream
Outlet One work stream
Versi on 10
Chapter 7
The outl et stream must be the same type (materi al , heat, or work) as the i nl et
stream.
Specifying Mult
The stream mul ti pl i cati on factor, speci fi ed on the I nput Speci fi cati ons sheet, i s
the onl y i nput requi red for Mul t. Thi s factor has to be posi ti ve for materi al
streams. You can speci fy ei ther a posi ti ve or negati ve factor for heat or work
streams, thus al l owi ng a change i n di recti on for the heat or work fl ow.
Use the I nput Di agnosti cs sheet to overri de gl obal val ues for the stream and
si mul ati on message l evel s speci fi ed on the Setup Speci fi cati ons Di agnosti cs
sheet.
Thi s model has no dynami c features. For materi al stream mul ti pl i ers the
pressure of each outl et stream i s equal to the pressure of the i nl et stream. The
fl ow rate of each outl et stream i s equal to the fl ow rate of the i nl et stream
mul ti pl i ed by the factor as speci fi ed i n the steady-state si mul ati on.
Versi on 10
Manipulators
Dupl
Stream Duplicator
Dupl copi es an i nl et stream (materi al , heat, or work) to any number of dupl i cate
outl et streams. I t i s useful for si mul taneousl y processi ng a stream i n di fferent
types of uni ts. Sel ect the Heat (Q) and Work (W) Dupl i cons from the Model
Li brary for heat and work streams respecti vel y. Dupl does not mai ntai n heat or
materi al bal ances.
Flowsheet Connectivity for Dupl
Material
Material
(any number)
Flowsheet for Duplicating Material Streams
Material Streams
Outlet At l east one materi al stream, whi ch i s a copy of the i nl et stream
Heat
Heat
(any number)
Flowsheet for Duplicating Heat Streams
Heat Streams
Inlet One heat stream
Outlet At l east one heat stream, whi ch i s a copy of the i nl et stream
Versi on 10
Chapter 7
Work
Work
(any number)
Flowsheet for Duplicating Work Streams
Work Streams
Inlet One work stream
Outlet At l east one work stream, whi ch i s a copy of the i nl et stream
Specifying Dupl
Dupl requi res no i nput parameters. Use the I nput Di agnosti cs sheet to overri de
gl obal val ues for the stream and si mul ati on message l evel s speci fi ed on the Setup
Speci fi cati ons Di agnosti cs sheet.
Thi s model has no dynami c features. For materi al stream dupl i cators the
pressure of each outl et stream i s equal to the pressure of the i nl et stream. The
fl ow rate of each outl et stream i s equal to the fl ow rate of the i nl et stream.
Versi on 10
Manipulators
ClChng
Stream Class Changer
Cl Chng changes the stream cl ass between bl ocks and fl owsheet secti ons. You can
use Cl Chng to add or del ete empty sol i d substreams between fl owsheet secti ons.
Cl Chng does not represent a real uni t operati on.
Flowsheet Connectivity for ClChng
Feed Product
Material Streams
Outlet One materi al product stream
Specifying ClChng
Cl Chng does not requi re i nput. I t copi es substreams from the i nl et stream to the
correspondi ng substreams of the outl et stream.
If a substream is Then ClChng
In the outlet but not in the inlet Initializes the substream to zero flow
In the inlet but not in the outlet Drops the substream
Cl Chng does not mai ntai n mass and energy bal ances i f any dropped substream
contai ns materi al fl ow or heat/work i nformati on.
O O O O
Versi on 10
Chapter 8
8 Solids
Thi s chapter descri bes the uni t operati on model s for sol i ds processi ng such as
crystal l i zers, sol i d crushers and separators, gas-sol i d separators, l i qui d-sol i d
separators, and sol i ds washers. The model s are:
Crystallizer Crystallizer Produces crystals from solution based on
solubility
Mixed suspension, mixed product removal
(MSMPR) crystallizer
Crusher Solids crusher Breaks solid particles to reduce particle
size
Wet and dry crushers, primary and
secondary crushers
Screen Solids separator Separates solid particles based on particle
size
Upper and lower
dry and wet screens
FabFl Fabric filter Separates solids from gas using fabric
filter baghouses
Rating and sizing baghouses
Cyclone Cyclone
separator
Separates solids from gas using gas
vortex in a cyclone
Rating and sizing cyclones
VScrub Venturi scrubber Separates solids from gas by direct
contact with an atomized liquid
Rating and sizing
venturi scrubbers
ESP Electrostatic
precipitator
Separates solids from gas using an
electric charge between two plates
Rating and sizing dry electrostatic
precipitators
HyCyc Hydrocyclone Separates solids from liquid using liquid
vortex in a hydrocyclone
Rating or sizing hydrocyclones
CFuge Centrifuge filter Separates solids from liquid using a
rotating basket
Rating or sizing centrifuges
Filter Rotary vacuum
filter
Separates solids from liquid using a
continuous rotary vacuum filter
Rating or sizing rotary vacuum filters
SWash Single-stage
solids washer
Models recovery of dissolved components
from an entrained liquid of a solids stream
using a washing liquid
Single -stage solids washer
CCD Counter-current
decanter
Models multi-stage recovery of dissolved
components from an entrained liquid of a
solids stream using a washing liquid
Multi-stage solids washers
Versi on 10
Solids
Thi s chapter i s organi zed i nto the fol l owi ng secti ons:
Section Models
Crystallizer Crystallizer
Crushers and Screens Crusher, Screen
Gas-Solid Separators FabFl, Cyclone, VScrub, ESP
Liquid-Solid Separators HyCyc, CFuge, Filter
Solids Washers SWash, CCD
Versi on 10
Chapter 8
Crystallizer
Mixed Suspension Mixed Product Removal Crystallizer
Crystal l i zer model s a mi xed suspensi on, mi xed product removal (MSMPR)
crystal l i zer. I t performs mass and energy bal ance cal cul ati ons and opti onal l y
determi nes the crystal si ze di stri buti on.
Crystal l i zer assumes that the product magma l eaves the crystal l i zer i n
equi l i bri um, so the mother l i quor i n the product magma i s saturated.
The feed to Crystal l i zer mi xes wi th reci rcul ated magma and passes through a
heat exchanger before i t enters the crystal l i zer.
The product stream from Crystal l i zer contai ns l i qui ds and sol i ds. You can pass
thi s stream through a hydrocycl one, fi l ter, or other fl ui d-sol i d separator to
separate the phases. Crystal l i zer can have an outl et vapor stream.
Flowsheet Connectivity for Crystallizer
Material
(any number)
Heat
(optional)
Vapor
(optional)
Heat
(optional)
Liquid
and Solid
Material Streams
Outlet One materi al stream for l i qui d and sol i d
One opti onal vapor stream
The outl et materi al stream shoul d normal l y have at l east one sol i d substream for
the crystal s formed. I f you sel ect Cal cul ate PSD from Growth Ki neti cs or User-
Speci fi ed Val ues on the PSD PSD sheet, each substream must have a parti cl e
si ze di stri buti on (PSD) attri bute.
Versi on 10
Solids
I f el ectrol yte sal ts are formed based on el ectrol yte chemi stry cal cul ati ons, a sol i d
substream i s not requi red when you sel ect Copy from I nl et Stream on the PSD
PSD sheet.
I f you do not use the vapor outl et stream, vapor products wi l l be pl aced i n the
l i qui d/sol i d product stream.
Heat Streams
Inlet Any number of opti onal i nl et heat streams
Outlet One opti onal outl et heat stream
I f you gi ve onl y one speci fi cati on on the Setup Speci fi cati ons sheet (temperature
or pressure), Crystal l i zer uses the sum of the i nl et heat streams as a duty
speci fi cati on. Otherwi se, Crystal l i zer uses the i nl et heat streams onl y to
cal cul ate the net heat duty. The net heat duty i s the sum of the i nl et heat
streams mi nus the actual (cal cul ated) heat duty.
Specifying Crystallizer
Crystal l i zer cal cul ates crystal product fl ow rate and/or vapor fl ow, based on
sol ubi l i ty data you suppl y. Or you can speci fy the chemi stry for el ectrol yte systems
i nstead of speci fyi ng sol ubi l i ty data.
You must speci fy two of the fol l owi ng:
Crystal l i zer temperature
Pressure or pressure drop
Heat duty for the heat exchanger
Crystal product fl ow rate
Vapor fl ow
If you specify Crystallizer calculates
Temperature and Pressure Heat duty, crystal product flow rate, vapor flow rate
Pressure and Heat Duty Temperature, crystal product flow rate, vapor flow rate
Temperature and Heat Duty Pressure, crystal product flow rate, vapor flow rate
Pressure and Crystal Product Flow Rate Temperature, heat duty, vapor flow rate
Temperature and Crystal Product Flow Rate Pressure, heat duty, vapor flow rate
Pressure and Vapor Flow Rate Temperature, heat duty, crystal product flow rate
Temperature and Vapor Flow Rate Pressure, heat duty, crystal product flow rate
Versi on 10
Chapter 8
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Crystal l i zer:
Setup Specify operating parameters, crystal product and solubility parameters,
recirculation options, and flash convergence parameters
PSD Specify PSD and crystal growth calculation parameters
Advanced Specify component attributes, convergence parameters, and name and parameters
for user solubility subroutine
Results View summary of Crystallizer results, material and energy balance results, and
crystal size distribution results
Recirculation Specifications
You can model crystal l i zer wi th or wi thout magma reci rcul ati on. To acti vate
reci rcul ati on, speci fy one of the fol l owi ng on the Setup Reci rcul ati on sheet:
Reci rcul ati on fracti on
Reci rcul ati on fl ow rate
Temperature change across heat exchanger
I f you want to model a di fferent crystal l i zati on process fl owsheet, you can use
Crystal l i zer wi thout reci rcul ati on, and use other bl ocks i n the fl owsheet to model
the reci rcul ati on.
Solubility
Crystal l i zer cal cul ates the amount of crystal produced at i ts saturati on (cl ass I I
crystal l i zati on). You can provi de sol ubi l i ty data i n one of these ways:
Enter sol ubi l i ty data on the Setup Sol ubi l i ty sheet
Reference an el ectrol yte chemi stry (defi ned i n the Reacti ons Chemi stry
forms) i n whi ch the crystal l i zi ng component has been decl ared as a "sal t"
Suppl y a subrouti ne to provi de the saturati on concentrati on or to cal cul ate
crystal product fl ow rate di rectl y
Versi on 10
Solids
Saturation Calculation Method
Choose the saturati on cal cul ati on method from these opti ons:
Sol ubi l i ty method: I denti fy the crystal l i zi ng component as sol i d product on
the Setup Crystal l i zati on sheet. Enter sol ubi l i ty data on the Setup Sol ubi l i ty
sheet. Thi s data appl i es to the reactant speci es i n the mi xed substream.
Chemi stry method: Create a new Chemi stry on the Reacti ons Chemi stry
object manager. Enter the crystal l i zati on as a sal t reacti on on the Reacti ons
Stoi chi ometry sheet. On the Bl ockOpti ons Properti es sheet of the crystal l i zer,
enter the Chemi stry I D and sel ect True Speci es for Si mul ati on Approach. You
must speci fy the crystal l i zi ng component as a Sal t Component I D on the
Setup Speci fi cati ons sheet.
User Subrouti ne method: I denti fy the crystal l i zi ng component on the Setup
Crystal l i zati on sheet and the sol ubi l i ty data basi s and sol vent I D on the
Setup Sol ubi l i ty sheet. Speci fy a user subrouti ne to cal cul ate saturati on
concentrati on or crystal l i zer yi el d on the Advanced UserSubrouti ne sheet.
I n general , when usi ng the Sol ubi l i ty method, you shoul d bl ank out the
Chemi stry I D fi el d on the Bl ockOpti ons Properti es sheet. I f you speci fy chemi stry
when usi ng the Sol ubi l i ty method, the chemi stry must not contai n the
crystal l i zi ng component.
Supersaturation
The degree of supersaturati on i s the dri vi ng force for crystal l i zati on processes.
Supersaturati on i s defi ned as:
S C C
s

Where:
S = Supersaturati on (kg of sol ute/m
3
of sol uti on)
C = Sol ute concentrati on
C
s
= Sol ute saturati on concentrati on
Because the crystal l i zer model assumes that the product magma i s i n phase
equi l i bri um, thi s equati on i s not used. I t i s provi ded onl y for reference.
Versi on 10
Chapter 8
Crystal Growth Rate
The crystal growth rate can be expressed as a functi on of the degree of
supersaturati on (S):
G k S
o
g
n
Where:
G
o
= Growth rate dependence on supersaturati on (m/s)
k
g
= Growth rate expressi on coeffi ci ent
n = Exponent
Thi s expressi on i s provi ded as background i nformati on onl y.
I n ASPEN PLUS, G
o
i s cal cul ated i mpl i ci tl y from the thi rd moment of the
popul ati on densi ty.
For a si ze-dependent growth rate, the growth rate i s a functi on of crystal
l ength (L):
G G L
o
+ ( ) 1
For 0 1
Where:
= Constant
= Exponent
I f the growth rate i s i ndependent of crystal si ze, then the val ues for and are
set to zero.
Versi on 10
Solids
Crystal Nucleation Rate
The overal l nucl eati on rate can be expressed as the sum of speci fi c contri buti ng
factors (Bennett, 1984)
1
:
B k G M R
o
b
i
T
j k
Where:
B
o
= Overal l nucl eati on rate
i , j, k = Exponents
k
b
= Overal l nucl eati on rate expressi on coeffi ci ent
M
T
= Magma densi ty = P/q (kg/m
3
)
G = Crystal growth rate
R = I mpel l er rotati on rate (revs/s)
P = Crystal mass fl ow rate (kg/s)
q = Vol umetri c fl ow rate of sl urry i n the di scharge (m
3
/s)
Population Balance
I f the feed stream contai ns no crystal s, the popul ati on bal ance for a wel l -mi xed
conti nuous crystal l i zer can be wri tten as (Randol ph and Larson, 1988)
2
:
d nG
dL
qn
V
( )
+ 0
Where:
G = Crystal growth rate
n = Popul ati on densi ty (no. /m
3
/m)
L = Crystal l ength (m)
V = Crystal l i zer vol ume (m
3
)
q = Vol umetri c fl ow rate of sl urry i n the di scharge (m
3
/s)
Versi on 10
Chapter 8
The boundary condi ti on i s n n
o
at L =0, where n B G
o o
/ i s the popul ati on
densi ty of nucl ei . For a constant crystal growth rate, the popul ati on densi ty i s:
n L n
L
G
o
( )
1
]
1
exp
where V / q i s the crystal resi dence ti me.

PSD Statistics
ASPEN PLUS cal cul ates the crystal si ze di stri buti on stati sti cs once you sel ect
the Cal cul ate PSD from Growth Ki neti cs opti on on the PSD PSD sheet.
Properti es of the di stri buti on may be eval uated from the moment equati ons. The
j-th moment of the parti cl e si ze di stri buti on i s defi ned as:
m L n L dL
j
j
0
( )
The system reports several crystal si ze di stri buti on stati sti cs, measured on a
vol ume or mass basi s, i ncl udi ng:
Mean si ze
Standard devi ati on
Skewness
The coeffi ci ent of vari ati on (expressed as a percentage)
The mean si ze i s the mass-wei ghted average crystal si ze, as determi ned by the
rati o of the fourth moment to the thi rd moment, as fol l ows:
L
m
m
4
3
The skewness of a symmetri c si ze di stri buti on about the mean i s zero. Negati ve
val ues of skewness i ndi cate the di stri buti on i s skewed toward the presence of
smal l crystal s. Posi ti ve val ues of skewness i ndi cate the crystal di stri buti on
contai ns an excess of l arge crystal s.
Skewness i s defi ned as
f ( )
( )
x mean
standard deviation
3
3
Versi on 10
Solids
The system uses the coeffi ci ent of vari ati on to cal cul ate vari ati on rel ated to the
cumul ati ve vol ume (or mass) di stri buti on.
Coeff Var(%)
100
84 16
2 50
pd pd
pd
@(. ) @(. )
@(. )
where pd@ (x) i s the parti cl e di ameter correspondi ng to fracti on x of the
cumul ati ve vol ume (or mass) di stri buti on. The fracti on can be entered as the
Fracti onal Coeffi ci ent on the PSD Crystal Growth sheet; otherwi se, i t defaul ts to
.16.
Calculating PSD
The magma densi ty, defi ned as total mass of crystal s per uni t vol ume of sl urry,
can be obtai ned from the thi rd moment:
M k L n L dL
T c v
0
3
( )
Where:
c
= Densi ty of crystal (kg/m
3
)
k
v
= Vol ume shape factor of the crystal
Si nce:
n L n
L
G
o
( )
1
]
1
exp
,
n
B
G
o
o
o
,
and B k G M R
o
b
i
T
j k
these equati ons can be substi tuted i nto the thi rd moment of popul ati on densi ty,
yi el di ng:
M k L k
G
G
M R
L
G
dL
T c v b
i
o T
j k
1
]
1
3
0
exp
where G G L
o
+ ( ) 1
.
Because L i s made di screte by the i ncrements of the parti cl e si ze di stri buti on, the
equati ons can be sol ved for G
o
.
Versi on 10
Chapter 8
References
1. Bennett, R.C. "Crystal l i zati on from Sol uti on," Perrys Chemical Engineers
Handbook, 6th Ed., pp. 19.24-19.40, McGraw-Hi l l , 1984.
2. Randol ph, A.D. and Larson, M.A., Theory of Particulate Processes, 2nd Ed.,
Academi c Press, 1988.
Versi on 10
Solids
Versi on 10
Chapter 8
Crusher
Solids Crusher
Use Crusher to si mul ate the breaki ng of sol i d parti cl es.
Crusher can model the wet or dry conti nuous operati on of:
Gyratory/jaw crushers
Si ngl e-rol l crushers
Mul ti pl e-rol l crushers
Cage mi l l i mpact breakers
Crusher assumes the feed i s homogeneous. The breaki ng process creates
fragments wi th the same composi ti on as the feed. Crusher cal cul ates the power
requi red for crushi ng, and the parti cl e si ze di stri buti on of the outl et sol i ds
stream.
Crusher does not account for the heat produced by the breaki ng process.
Flowsheet Connectivity for Crusher
Feed
Crushed Solids
Work (optional)
Material Streams
Inlet One materi al stream wi th at l east one sol i ds substream
Each sol i ds substream must have a parti cl e si ze di stri buti on (PSD) attri bute.
Versi on 10
Solids
Work Streams
Inlet No i nl et work streams
Outlet One work stream contai ni ng the cal cul ated power requi rement
(opti onal )
Specifying Crusher
Use the I nput Speci fi cati ons and Gri ndabi l i ty sheets to speci fy operati ng
condi ti ons. You must enter the type of crusher and maxi mum parti cl e di ameter on
the I nput Speci fi cati ons sheet. You must al so speci fy the Bond work i ndex or the
Hardgrove gri ndabi l i ty i ndex for each sol i ds substream on the Gri ndabi l i ty sheet.
The outl et fl ow rate of crushed product i n the k-th si ze i nterval i s:
[ ]
P F S B S F
k
j i
ij i ik
j
k kj
( ) ( ( ) ( ) +

) 1
Where:
B
ik
= Breakage functi on. Fracti on of parti cl es ori gi nal l y i n si ze
i nterval i that end up i n si ze i nterval k
F
ij
= Fl ow rate of feed i n the si ze i nterval i and parti cl e si ze
di stri buti on j
P
k
= Fl ow rate of sol i d i n si ze i nterval k
Si = Sel ecti on functi on. Fracti on of feed parti cl es i n si ze i nterval i
to be crushed at the outl et di ameter
S
k
= Sel ecti on functi on. Fracti on of feed parti cl es i n si ze i nterval
k to be crushed at the outl et di ameter
= Crusher outl et di ameter (Maxi mum Parti cl e Di ameter fi el d)
i
= Si ze i nterval counter wi thi n a PSD
j
= PSD counter for mul ti pl e si ze di stri buti on
I f the i nl et stream contai ns no l i qui d, then Crusher assumes dry crushi ng, and
power requi rements i ncrease by 34%.
Versi on 10
Chapter 8
You can enter tabul ar val ues for the breakage ( ) B
ik
functi on on the I nput
BreakageFuncti on sheet and for the sel ecti on ( ) S
i
functi on on the I nput
Sel ecti onFuncti on sheet, or l et Crusher use the bui l t-i n tabl es (U.S. Bureau of
Mi nes, 1977) (see the fol l owi ng two tabl es).
Breakage Function Correlations B
ik
( )
Feed size/solids outlet diameter >1.7
Feed size/solids
outlet diameter <1.7
Ratio of product size to
feed size
Multiple roll
crusher
Gyratory/jaw
crusher
Single roll
crusher
Cage mill
crusher All crushers
1.0 1.0 1.0 1.0 1.0 1.0
0.8308 0.95 0.95 0.96 0.84 0.8972
0.5882 0.85 0.85 0.79 0.50 0.7035
0.4176 0.65 0.70 0.45 0.32 0.54
0.2065 0.35 0.35 0.20 0.15 0.2952
0.1041 0.22 0.20 0.10 0.052 0.1564
0.0522 0.14 0.19 0.05 0.019 0.0805
0.0368 0.11 0.17 0.03 0.011 0.0572
0.026 0.09 0.12 0.02 0.0066 0.0406
0.0131 0.03 0.08 0.0 0.002 0.0206
0.0 0.0 0.0 0.0 0.0 0.0
Selection Function Correlations, S
i
( )
Ratio of feed size to
outlet diameter Primary crusher Secondary crusher
0.95 0.5695 0.7693
0.9 0.3817 0.6962
0.8 0.1716 0.5695
0.7 0.0771 0.4667
0.6 0.0347 0.3817
0.5 0.0156 0.3128
0.4 0.007 0.256
0.3 0.00315 0.2096
0.2 0.00145 0.1716
continued
Versi on 10
Solids
Ratio of feed size to
outlet diameter Primary crusher Secondary crusher
0.1 0.0006 0.1405
0.05 0.00043 0.1271
0.001 0.00026 0.1153
0.0001 0.00026 0.1148
I f the rati o of feed si ze to outl et di ameter i s greater than 1.0, then S
i
( ) . 0 85 .
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Crusher:
Input Enter crusher operating parameters, the Bond work index or the Hardgrove
grindability index, and user-specified selection and breakage functions
Results View summary of Crusher results and material and energy balances
Primary and Secondary Crushers
Crushi ng operati ons are usual l y performed i n stages. The reducti on rati o i s the
rati o of the maxi mum di ameter of feed parti cl es to product parti cl es. The
reducti on rati o i n crushers ranges from 3 to 6 per stage. Feed parti cl es are fed to
the pri mary crushers. Outl et parti cl es from the pri mary crushers are reduced
further by the secondary crushers.
Crusher uses di fferent correl ati ons for pri mary and secondary crushers. Use the
Operati ng Mode fi el d on the I nput Speci fi cati ons sheet to enter the type of
crusher.
To i mprove the effi ci ency of mul ti stage crushers, use screens between stages.
Power Requirement
The fol l owi ng equati on determi nes the power requi rement for Crusher:
( )
POWER
X X BWI FLOWT
X X
F p
F p
001 .
Versi on 10
Chapter 8
Where:
POWER = Requi red power (Watt)
X
F
= Di ameter l arger than 80% of feed parti cl e mass (m)
X
P
= Di ameter l arger than 80% of product parti cl e mass (m)
BWI = Bond work i ndex
FLOWT = Total sol i ds mass fl ow rate (kg/s)
For dry crushi ng, power requi rement i ncreases by 34%.
I f X
p
i s l ess than 70 mi crometers, then the power requi red i s further adjusted
by:
POWER POWER
X
X
p
p
_
,
10 6 10
1145
6
.
.
Bond Work Index
The Bond equati on defi nes the work consumed i n si ze reducti on:
E E
X X
X X
i
F P
F
P
100
Where:
E
= Work requi red to reduce a uni t wei ght of feed wi th 80%
passi ng a di ameter X
F
mi crons to a product wi th 80%
passi ng a di ameter X
p
mi crons
E
i
= Bond work i ndex, that i s, the work requi red to reduce a uni t
wei ght from a theoreti cal i nfi ni te si ze to 80% passi ng a
di ameter of 100 mi crometers
The Bond work i ndex i s a semi -empi ri cal parameter that depends on the properti es
of the materi al processed. The Bond work i ndi ces have been measured
experi mental l y for a wi de range of materi al s, and are avai l abl e i n Perrys Chemical
Engineers Handbook. Use experi mental val ues wi th cauti on. The Bond work i ndex
i s al so a functi on of the:
Parti cl e si ze for non-homogeneous materi al s
Effi ci ency of the si ze-reducti on equi pment
Versi on 10
Solids
Hardgrove Grindability Index
The Hardgrove gri ndabi l i ty i ndex i ndi cates the di ffi cul ty of gri ndi ng coal based on
physi cal properti es such as hardness, fracture, and tensi l e strength. The
Hardgrove gri ndabi l i ty i ndex can be approxi mated by:
BWI
HGI
435
0 91 .
Where:
BWI = Bond work i ndex
HGI = Hardgrove gri ndabi l i ty i ndex
The HGI for some Uni ted States coal s are avai l abl e i n Perrys Chemical
Engineers Handbook.
References
1. Computer Simulation of Coal Preparation Plants, U.S. Bureau of Mi nes,
Grant No. GO-155030, Fi nal Report August (1977).
2. Perrys Chemical Engineers Handbook, 6
th
Ed., McGraw Hi l l , 1984.
Versi on 10
Chapter 8
Screen
Solids Separator
Screen si mul ates the separati on by screens of a mi xture contai ni ng vari ous si zes of
sol i d parti cl es i nto parti cl es that have more uni form si zes than the ori gi nal
mi xture. You can use Screen to model wet or dry operati ons and upper or l ower
l evel screens.
Screen cal cul ates the separati on effi ci ency of the screen from the si ze of screen
openi ngs you speci fy.
Flowsheet Connectivity for Screen
Feed
Overflow
Underflow
Material Streams
Outlet One materi al stream for parti cl es that do not pass through the
screen (overfl ow)
One materi al stream for parti cl es that pass through the screen
(underfl ow)
Each sol i ds substream must have a parti cl e si ze di stri buti on attri bute.
Specifying Screen
Use the I nput Speci fi cati ons sheet to enter:
Screen si ze openi ng
Operati ng l evel (Upper or Lower)
Operati ng mode (Wet or Dry)
Entrai nments
Versi on 10
Solids
You can al so use the I nput Sel ecti onFuncti on sheet to enter the fol l owi ng
functi ons:
Sel ecti on functi on ( S
i
) (opti onal )
Separati on strength (opti onal )
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Screen:
Input Specify screen parameters, operating conditions, and user-specified screen
separation strength and selection functions
Results View summary of Screen results and material and energy balances
Upper and Lower Level Screens
You can speci fy the operati ng l evel as Upper or Lower. The most effi ci ent
confi gurati on i s a mul ti pl e-deck screen wi th a seri es of Screen bl ocks. The i nl et
stream i s fed over the upper l evel screen. The underfl ow from the upper l evel
screens i s fed over the l ower l evel screens. Screen uses di fferent correl ati ons for
upper and l ower l evel screens.
Screen cal cul ates the fl ow rate of the screen overfl ow stream as:
F S F
o i
i
ij
j

Where:
S
i
= Sel ecti on functi on. The fracti on of feed parti cl es i n si ze range
i that passes over the screen i nto the overfl ow product
F
ij
= Fl ow rate of feed i n si ze range i and parti cl e si ze di stri buti on
attri bute j
Selection Function and Separation Strength
Screen cal cul ates the sel ecti on functi on for a certai n si ze i nterval as:
( )
[ ]
S
A d S
for d S
i
p o
p o
<
1
1 exp
S for d S
i p o
1
Versi on 10
Chapter 8
Where:
d
p
= Parti cl e di ameter
S
o
= Si ze of screen openi ng
A = Separati on strength
The defaul t val ue of the screen separati on strength, A, i s a functi on of the si ze of
the screen openi ng. Screen has four bui l t-i n functi ons (U.S. Bureau of Mi nes,
1977)
1
for al l possi bl e combi nati ons of screen types (see the table, Screen Separation
Strength/Screen Size Correlation):
Upper l evel dry
Lower l evel dry
Upper l evel wet
Lower l evel wet
You can enter your own separati on strength val ue, separati on strength correl ati on
or sel ecti on functi on correl ati on on the I nput Sel ecti onFuncti on sheet. Screen then
uses these sel ecti on functi on val ues for i ts mass bal ance cal cul ati on.
Screen Separation Strength/Screen Size Correlation
Size of screen
opening (m) Dry, upper level Dry, lower level Wet, upper level Wet, lower level
0.457 60 60 60 60
0.152 20 20 20 20
0.038 8 8 9 9
0.0095 8 6 8.5 6.6
0.00635 5 4 5.5 4.5
0.00236 3 2 3.5 2.3
0.00059 0.7 0.7 0.8 0.8
0.00042 0.6 0.6 0.7 0.7
0.000295 0.5 0.5 0.55 0.55
Separation Efficiency
The separati on effi ci ency of the screen i s cal cul ated as the rati o of the mass fl ow
rate of the underfl ow to the fracti on of the feed fl ow rate contai ni ng parti cl es
smal l er than the screen openi ngs.
Versi on 10
Solids
References
Computer Simulation of Coal Preparation Plants, U.S. Bureau of Mi nes, Grant
No. GO-155030, Fi nal Report August (1977).
Versi on 10
Chapter 8
FabFl
Fabric Filter
FabFl i s a gas-sol i ds separator model used to separate an i nl et gas stream
contai ni ng sol i ds i nto a sol i ds stream and a gas stream carryi ng the resi dual
sol i ds. Use FabFl to si mul ate or desi gn baghouse uni ts i n whi ch sol i d parti cl es
are separated from the i nl et gas stream. A baghouse consi sts of a number of cel l s
i n whi ch verti cal l y-mounted cyl i ndri cal fabri c fi l ter bags operate i n paral l el .
You can use FabFl to rate or si ze baghouses.
Flowsheet Connectivity for FabFl
Feed
Gas (overflow)
Solids (underflow)
Material Streams
Outlet One overfl ow stream for the cl eaned gas
One underfl ow stream for the sol i ds parti cl es
Sol i ds may be entrai ned i n the overfl ow, based on the separati on effi ci ency.
Specifying FabFl
Use the I nput Speci fi cati ons sheet to speci fy operati ng condi ti ons and baghouse
characteri sti cs.
For these calculations Set Mode= And number of cells is
Rating Simulation Specified
Sizing Design Calculated
Versi on 10
Solids
For si zi ng or rati ng cal cul ati ons:
If you enter FabFl calculates
Maximum allowable pressure drop Filtration time
Filtration time Pressure drop
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for FabFl :
Input Enter operating conditions, baghouse characteristics, and separation
efficiency
Results View summary of FabFl results and material and energy balances
Operating Ranges
FabFl uses empi ri cal model s because no theoreti cal model s exi st. Expect unrel i abl e
resul ts when operati ng condi ti ons exceed the ranges of the experi mental data on
whi ch the model s are based. Your data shoul d fal l wi thi n these ranges:
Di ameter of sol i d parti cl es between 10
7
to 10
4
m (0.1 to 100 mi crometers)
Maxi mum gas vel oci ty through the cl oth between 0.1 and 0.2 m/s (20 to 40
ft/mi n)
Filtering Time
When rati ng fabri c fi l ters, FabFl cal cul ates the fi l teri ng ti me t as:
t
P P
CKV
f i
o

2
Where:
f
P
= Fi nal pressure drop across col l ected dust and fi l ter cl oth
i
P
= Pressure drop of the cl ean bag
C = Dust concentrati on
K = Dust resi stance coeffi ci ent
o
V
= Ai r to cl oth rati o (gas vel oci ty through the cl oth)
Versi on 10
Chapter 8
The ai r to cl oth rati o V
o
i s:
V
Q
N N A N
o
cell shake bag bag
( )
Where:
Q = Vol umetri c fl ow rate of the gas
N
cell
= Number of cel l s
N
shake
= Number of cel l s bei ng cl eaned
A
bag
= Total fi l ter surface of al l bags
N
bag
= Number of bags per cel l
Resistance Coefficient
The resi stance coeffi ci ent K depends on the parti cl e si ze and nature of sol i d
parti cl es. I n an i ndustri al -scal e baghouse, the resi stance coeffi ci ent al so vari es
wi th ti me and bag posi ti on. I f speci fi c resi stance coeffi ci ents are not avai l abl e,
the fol l owi ng val ues can be used as rough esti mates
1
:
Dust particle diameter
( 10
6
m)
Resistance coefficients
[Pa/(kg/m
2
) (m/s)]
Less than 20 300,000
20 to 90 60,000
Greater than 90 15,000
These coeffi ci ents were determi ned from a smal l fabri c fi l ter. The fi l ter has an ai r
fl ow of 2 ft
3
/mi n through 0.2 ft
2
of cl oth area (a fi l teri ng gas vel oci ty of 10
ft/mi n). The pressure drop across the bag and dust was 8 i nches of H O
2
.
An approxi mati on for the resi stance coeffi ci ent
2
i s:
K
d
p
1000
2
Where:
d
p
= The average parti cl e si ze i n mi crons
The uni ts for K are (inches of water)/ (lbs dust/ ft
2
of area)(ft/ min velocity).
Versi on 10
Solids
The overal l separati on effi ci ency of the baghouse i s:
o
j i
ij ij
S
Total inlet flow rate of solids
flow rate of solids removed from the inlet
total inlet flow rate of solids

Where:
S
ij
= Fl ow rate of sol i d j i n si ze i ncrement i
I n FabFl , the separati on effi ci ency i s a functi on of the parti cl e di ameter of the
sol i ds. For l arge parti cl es (greater than 10 mi crometers i n di ameter), fracti onal
col l ecti on effi ci ency ( )
i
i s 1.0. For parti cl es smal l er than 10 mi crometers,
effi ci ency decreases rapi dl y.
i
When
1.0 ( ) d m
p av
>10
0.0011 ( ) d
p av
+ 0.989 1 10 m (d
p
< < )
av
m
0.495 ( ) d
p av
+ 0.495 ( ) d
p av
<1m
You al so can enter effi ci ency as a functi on of parti cl e si zes on the I nput Effi ci ency
sheet to overri de the bui l t-i n correl ati ons.
References
1. Air Pollution Engineering Manual, Publ i c Heal th Servi ce Publ i cati on No. 999-
AP-40, pp. 106-135, Washi ngton D.C., DHEW (1967).
2. Bi l l i ngs, C.E. and Wi l der, J., Handbook of Fabric Filter Technology, Vol . I ,
NI I S PB 200648.
Versi on 10
Chapter 8
Cyclone
Cyclone Separator
Cycl one separates an i nl et gas stream contai ni ng sol i ds i nto a sol i ds stream and a
gas stream carryi ng the resi dual sol i ds.
Use Cycl one to si mul ate cycl one separators i n whi ch sol i d parti cl es are removed by
the centri fugal force of a gas vortex. You can use Cycl one to si ze or rate cycl one
separators. I n si mul ati on mode, Cycl one cal cul ates the separati on effi ci ency and
pressure drop from a user-speci fi ed cycl one di ameter.
I n desi gn mode, the cycl one geometry i s cal cul ated to meet the user-speci fi ed
separati on effi ci enci es and maxi mum pressure drop. I n both cal cul ati on modes,
the parti cl e si ze di stri buti ons of the outl et sol i ds streams are determi ned.
Flowsheet Connectivity for Cyclone
Feed
Gas
Solids
Material Streams
Outlet One stream for the cl eaned gas
One stream for the sol i ds
Versi on 10
Solids
Specifying Cyclone
Use the I nput Speci fi cati ons sheet to speci fy the type of cycl one and operati ng
condi ti ons.
Use the I nput Di mensi ons sheet to enter cycl one di mensi ons, or use the I nput
Rati os sheet to enter rati os of cycl one di mensi ons.
To perform
these calculations Specify Cyclone calculates
Rating Simulation mode
Cyclone Diameter
Number of Cyclones
Separation efficiency
Pressure drop
Sizing Design mode
Maximum Pressure
Drop (optional)
Maximum Number of
Cyclones (optional)
Cyclone diameter
Number of cyclones
For rati ng cal cul ati ons, i f you speci fy Type=User-Speci fi ed or User-Speci fi ed
Rati os, you can speci fy cycl one di mensi ons on the I nput Di mensi ons or I nput
Rati os sheets.
For desi gn cal cul ati ons, you must al so enter the Maxi mum Number of Cycl ones
i n paral l el . I f ei ther of the fol l owi ng occurs, Cycl one cal cul ates the number of
cycl ones i n paral l el :
The effi ci ency of a si ngl e cycl one i s l ess than the requi red separati on effi ci ency.
The cal cul ated pressure drop exceeds the maxi mum pressure drop speci fi ed.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Cycl one:
Input Enter cyclone specifications, dimensions, dimension ratios, separation efficiencies,
and solids loading
Results View summary of Cyclone results and material and energy balances
Versi on 10
Chapter 8
The overal l separati on effi ci ency i s:
m
flow rate of solids removed from the inlet
total inlet flow rate of solids
m
o i
o
o o
o o o o
C C
C
Q C E
Q C
E
Q C
1
Where:
C
o
= Concentrati on of sol i ds i n i nl et gas
C
i
= Concentrati on of sol i ds i n outl et cl eaned gas
Q
o
= I nl et gas fl ow rate
E = Outl et emi ssi on rate of sol i ds i n the cl eaned gas
Cycl one attai ns hi gher separati on effi ci enci es wi th parti cl es that are 5 to 10
mi crons or greater i n di ameter. For parti cl es smal l er than 5 mi crons, Cycl one
effi ci ency decreases. Even wi th l arge parti cl es, i t i s di ffi cul t to obtai n a col l ecti on
effi ci ency greater than 95%.
I f you enter a desi gn effi ci ency hi gher than 95%, use ei ther:
Mul ti -stage cycl ones
Cycl one as a precl eaner, fol l owed by other col l ectors
You can speci fy the Effi ci ency Correl ati on fi el d on the I nput Speci fi cati ons sheet. I f
Effi ci ency Correl ati on=User-Speci fi ed, you can enter effi ci ency as a functi on of
parti cl e si zes on the I nput Effi ci ency sheet.
Operating Ranges
Cycl one uses correl ati ons that are semi -empi ri cal model s. Do not expect
sati sfactory accuracy when the speci fi ed condi ti ons exceed the ranges of
experi mental data from whi ch the model s were devel oped. I n general , the pressure
drop shoul d be l ess than 2500 N / m
2
(10 i nches of H O
2
). The operati ng pressure
shoul d not exceed atmospheri c pressure. The i nl et gas vel oci ty shoul d be i n the
range of 15 to 27 m/s (50 to 90 ft/s).
The Lei th and Li cht effi ci ency correl ati on i s accurate for i nl et vel oci ti es
approxi matel y 25 m/s (80 ft/s). The correl ati on overesti mates the separati on
effi ci ency at hi gh vel oci ti es.
Versi on 10
Solids
The Shepherd and Lappl e correl ati on i s accurate for parti cl e si zes of 5 to 200
mi crons. Thi s correl ati on tends to overesti mate the effi ci ency of l arge parti cl es
(greater than 200 mi crons). The Shepherd and Lappl e correl ati on al so
underesti mates the effi ci ency of fi ne parti cl es (smal l er than 5 mi crons).
Pressure Drop
Cycl one cal cul ates the pressure drop (Shepherd and Lapple, 1939)
1
as:
P U N
f t h
0.0030
2
Where:
f
= Densi ty of the fl ui d
U
t
= I nl et gas vel oci ty
N
h
= I nl et vel oci ty speeds
Use the I nput Sol i dsLoadi ng sheet to enter val ues to correct for sol i ds l oadi ng.
The i nl et vel oci ty speed, N
h
, i s:
N K
ab
D
k
e
2
Where:
K = Di mensi onl ess rati o
a = I nl et hei ght of the cycl one
b = I nl et wi dth of the cycl one
D
e
= Outl et di ameter of the cycl one
The di mensi onl ess rati o K i s:
c
nl s
abD
V V
K
) 2 / ( 8 +
Where:
V
s
= Annul ar shaped vol ume above the exi t duct to mi dl evel of
the entrance duct
V
nl
= Effecti ve vol ume of the cycl one cal cul ated by natural l ength l
D
c
= Body di ameter of the cycl one
Versi on 10
Chapter 8
The annul ar shaped vol ume V
s
above the exi t duct to mi dl evel of the entrance duct i s:
V
s a D D
s
c e
( / ) ( ) 2
4
2 2
Cyclone Diameter
Cycl one cal cul ates the di ameter of the body of the cycl one D
c
as:
D
b D
a D b D
c
f
p f
c
c c
1
]
1
1
0.0502
Q
(
2
)
( / )
( / ) ( / )
.
.
1
2 2
0 454
Where:
Q
= Overfl ow gas fl ow rate
f
= Densi ty of the fl ui d
= Vi scosi ty of gas fl ui d
p
= Densi ty of the parti cl es
I n thi s empi ri cal equati on, uni ts are:
Unit type Unit
Length Feet
Mass Pounds
Time Seconds
Dimension Ratios
Use the I nput Di mensi ons sheet to enter the di mensi ons of a cycl one when
Mode=Si mul ati on and Type=User-Speci fi ed. I f you speci fy Type=User-Speci fi ed
Rati os, you can use the I nput Rati os sheet to enter di mensi on rati os (di mensi on /
cycl one di ameter) for a cycl one.
Versi on 10
Solids
The di mensi on rati os and some defaul t val ues of the two bui l t-i n confi gurati ons
are:
Dimension ratio (dimension/cyclone diameter) Type = High efficiency Type = Medium efficiency
Cyclone diameter 1.0 1.0
Inlet height 0.5 0.75
Inlet width 0.2 0.375
Length of overflow 0.5 0.875
Diameter of overflow 0.5 0.75
Length of cone section 1.5 1.50
Overall length 4.0 4.0
Diameter of underflow 0.375 0.375
Number of gas turn in cyclone 7.0 4.0
Maximum diameter (m) 1.5 5.0
Minimum diameter (m) 0.1 0.1
Cycl one cal cul ates the di mensi ons of the bui l t-i n cycl ones usi ng these rati os and
the cycl one di ameter you speci fy. The bui l t-i n confi gurati ons (Type=Hi gh or
Medi um) may not be the best desi gns. I t i s recommended that you enter
di mensi ons or di mensi on rati os, i f avai l abl e.
Vane Constant
Use the Vane Constant fi el d on the I nput Speci fi cati ons sheet to speci fy the vane
constant. The vane constant vari es wi th the confi gurati on of the i nl et duct. I n the
common confi gurati on, the i nl et duct termi nates at the wal l of the cycl one. The
vane constant i s 16. To reduce fri cti on l oss, extend the duct i nto the i nteri or of the
cycl one. When the duct i s i n the mi ddl e of the cycl one separator, the vane constant
i s 7.5.
Cyclone Dimensions
The next fi gure shows the Cycl one geometry. The tabl e fol l owi ng the fi gure shows
the Cycl one di mensi ons.
Versi on 10
Chapter 8
a
D
e
D
c
b
s
h
H
B
Cyclone Geometry
The Cycl one desi gn confi gurati ons are:
Term Description High efficiency High throughput
D
c
Body diameter 1.0 1.0
a Inlet height 0.5 0.75
b Inlet width 0.2 0.375
s Outlet length 0.5 0.875
D
e
Outlet diameter 0.5 0.75
h Cylinder height 1.5 1.50
H Overall height 4.0 4.0
B Dust outlet diameter 0.375 0.375
Versi on 10
Solids
Solids Loading Correction
The feed concentrati on of sol i ds affects the separati on effi ci ency. Concentrati on
hi gher than 1 0
3
. gm m usual l y l eads to hi gher effi ci ency. Smol i k (1975)
2, 3
presented the fol l owi ng rel ati onshi p between the effi ci ency and sol i ds
concentrati on:
1
1
_
,
E
E
c
c
T
T
a
* *
Where:
c
*
=
"Low l oadi ng" sol i ds concentrati on, 1.0 gm/ m
3
c = Sol i ds concentrati on
E
T
*
= Total effi ci ency
E
T
= "Low l oadi ng" total effi ci ency
= Exponent
Smol i k gi ves val ues of 0.182. Thi s form can onl y serve as a gui de, because the
effect of dust concentrati on depends on the nature of the sol i ds, the humi di ty of the
gas, and many other factors that do not fi gure i n the exi sti ng correl ati ons.
The actual pressure drops wi th dust-l aden gases are normal l y l ower than those
obtai ned wi th cl ean gas. Smol i k gi ves an empi ri cal correl ati on for the effect of
feed concentrati on on pressure i n the form:
p
p
c
*
1
Where:
c =
Sol i ds concentrati on i n the feed, g / m
3
p * = Pressure drop
p = Pressure drop wi th cl ean gas
, = Constants dependi ng on the materi al
Smol i k gi ves val ues of 0.02 and 0.6.
Versi on 10
Chapter 8
References
1. Shepherd, G.B. and Lappl e, C.E., "Fl ow Pattern and Pressure Drop i n
Cycl one Dust Col l ectors," I ndustrial and Engineering Chemistry, 31, pp. 972-
984 (1939).
2. Smol i k, J. et al ., Ai r Pol l uti on Abatement, Part I . Scri ptum No. 401-2099 (i n
Czech). Techni cal Uni versi ty of Prague (1975). Quoted by Svarovsky, L.,
"Sol i d-Gas Separati on," Handbook of Powder Technology, Wi l l i ams, J.C. and
Al l en, T. (Eds.), Amsterdam: El sevi er, 1981.
3. Svarovsky, L., Solid-Gas Separation, Chapter 3, New York: El sevi er, 1981.
Versi on 10
Solids
VScrub
Venturi Scrubber
Use VScrub to si mul ate venturi scrubbers.
Venturi scrubbers remove sol i d parti cl es from a gas stream by di rect contact wi th
an atomi zed l i qui d stream.
You can use VScrub to rate or si ze venturi scrubbers.
Flowsheet Connectivity for VScrub
Gas
Liquid
Feed Gas
with Solids
Liquid and
Solids
Material Streams
Inlet One stream for sol i ds wi th at l east one sol i ds substream
One stream for the atomi zed l i qui d
Outlet One stream for the cl eaned gas
One stream for the l i qui d wi th sol i d parti cl es
Versi on 10
Chapter 8
Specifying VScrub
Use the VScrub I nput Speci fi cati ons sheet to speci fy operati ng condi ti ons and
parameters for si zi ng or rati ng cal cul ati ons.
To perform these
calculations Set Mode = Enter scrubber VScrub calculates
Rating Simulation Throat Diameter
Throat Length
Pressure drop
Sizing
Design Separation efficiency Liquid flow rate

Throat diameter
Throat length
Pressure drop
Because the requi red l i qui d fl ow rate i s vari ed to meet the effi ci ency, the materi al bal ance i s
not satisfied i f the cal cul ated l i qui d fl ow rate i s di fferent from the rate you enter.
I n both modes, VScrub al so cal cul ates the parti cl e si ze di stri buti ons of the sol i ds i n
the outl et streams.
VScrub assumes that the l i qui d stream i s i ntroduced before or at the begi nni ng of
the scrubber throat. I t al so assumes the separati on of the sol i d parti cl es from the
gas stream occurs onl y at the scrubber throat.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for VScrub:
Input Specify operating parameters and throat operating conditions
Results View summary of VScrub results and material and energy balances
Versi on 10
Solids
Pressure Drop
VScrub cal cul ates the pressure drop (Yung, S. et al ., 1977)
1
p across the throat of
the scrubber as:
( )
p
V
g
Q
Q
x x x
l t
c
l
g
_
,
+
2
1
2
2 4 2
Where:
l
= Densi ty of the l i qui d
V
t
= Rel ati ve vel oci ty of gas to l i qui d at the throat
g
c
= Conversi on factor i n Newtons l aw of moti on
Q
Q
l
g
= Li qui d to gas vol ume fl ow rate
x = Di mensi onl ess throat l ength defi ned by:
x
l C
D
t D g
d l
+
3
16
1
Where:
l
t
= Throat l ength
C
D
= Drag coeffi ci ent, as a functi on of the Reynol ds number
(Di cki nson and Marshal l , 1968)
2
N
Re
.
C
N
N
D
+ + . ( . )
.
22
24
1 015
0 6
Re
Re
g
= Densi ty of the gas
l
= Densi ty of the l i qui d
D
d
= Drop di ameter (Sauter mean), defi ned by (Nuki yama, S.,
Tanasawa, Y. 1939)
3
:
585
597
1000
0 5
0 45 1 5
V
Q
Q
t
l
l
l
l l
l
g
_
,
+
1
]
1
1
1
]
1
1
.
. .
Where:
l
= Surface tensi on
l
= Vi scosi ty of l i qui d
Versi on 10
Chapter 8
The separati on effi ci ency (Yung, S., et al ., 1978)
4
o
i s defi ned as:
o
Mass flow rate of particles in outlet liquid stream
Mass flow rate of particles in inlet gas stream
S
Total inlet flow rate of solids
i i
Where:
i
= Effi ci ency for si ze i ncrement i
S
i
= Mass fl ow rate of si ze i ncrement i
References
1. Yung, S. et al ., J ournal of the Air Pollution Control Association, 27, 348
(1977).
2. Di cki nson, D.R. and Marshal l , W.R., AI ChE J ournal, 14, 541, (1968).
3. Nuki yama, S. and Tanasawa, Y., Transcripts of the Society of Mechanical
Engineers (Japan), 5, 63 (1939).
4. Yung, S. et al ., Environmental Science and Technology, 12, 456 (1978).
Versi on 10
Solids
ESP
Electrostatic Precipitator
Use ESP to si mul ate dry el ectrostati c preci pi tators.
Dry el ectrostati c preci pi tators separate sol i ds from a gaseous stream.
El ectrostati c preci pi tators have verti cal l y mounted col l ecti ng pl ates wi th
di scharge wi res. The wi res are paral l el and posi ti oned mi dway between the
pl ates.
The corona di scharge of the hi gh-vol tage wi re el ectrodes fi rst charges the sol i d
parti cl es i n the i nl et gas stream. Then the el ectrostati c fi el d of the col l ecti ng
pl ate el ectrodes removes the sol i ds from the gas stream.
You can use ESP to si ze or rate el ectrostati c preci pi tators.
Flowsheet Connectivity for ESP
Feed
Gas
Solids
Material Streams
Outlet One materi al stream for the cl eaned gas
One materi al stream for the sol i ds
Versi on 10
Chapter 8
Specifying ESP
Use the I nput Speci fi cati ons sheet to speci fy parameters for si zi ng or rati ng
cal cul ati ons.
To perform these
calculations Set Mode= Enter ESP calculates
Rating Simulation Number of plates
Plate height
Plate length
Power required
Corona voltage
Pressure drop
Precipitator width
Sizing Design Separation efficiency Number of plates
Precipitator dimensions
Power required
Pressure drop
You can speci fy maxi mum di mensi ons for si zi ng cal cul ati ons on the I nput
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for ESP:
Input Specify operating parameters and dielectric constants and precipitator
dimensions
Results View summary of ESP results and material and energy balances
Operating Ranges
The vel oci ty of gas shoul d be between 1 and 2.5 m/sec (for pl ate spaci ng 200 and
300 mm). I f the gas vel oci ty i s l arger than 3 m/s or l ess than 0.5 m/s, then the
model s for effi ci ency and pressure drop are not val i d. Thi s i s because the transport
of fi ne parti cl es by turbul ent di ffusi on may become more si gni fi cant than transport
by el ectrostati c force.
ESP model s wi re-and-pl ate preci pi tators wi th rel ati vel y hi gh dust concentrati on
( ). 10
11
particles / m or 0.1 kg / m
3 3
I f the parti cl e concentrati on i s too l ow, ESP
may overesti mate the resul ts. ESP i s not sui tabl e for a cyl i ndri cal el ectrostati c
preci pi tator.
Versi on 10
Solids
The separati on effi ci ency i s defi ned as (Crawford, M. 1976)
1
:
ov
Mass outlet flow rate of solids
Total mass flow rate of the inlet solids substream
ov
nvs
nvo
s ps c
C
C
X L q E C
dWV

1
]
1
1
3
exp
( )
Where:
C
nvs
= Parti cl e concentrati on at X
s
C
nvo
= Parti cl e concentrati on at i nl et
X
s
= Poi nt at whi ch al l parti cl es have acqui red a saturati on charge
L
= Pl ate l ength
q
ps = Parti cl e saturati on charge
E
c
= Col l ecti ng fi el d strength ( . ( )) 0 25 E
o
C
= Conni ngham correcti on factor
= Vi scosi ty of the gas

d
= Parti cl e di ameter
W
= Di stance between wi res and pl ates
V
= Actual gas vel oci ty through the preci pi tator
The poi nt at whi ch al l parti cl es have acqui red a saturati on charge X
s
, i s defi ned
as:
X
dW s V C C
E C E Ws E r
s
w nvo nvs
o c c w
2
0 0
0332 08
( )
. ( . )
Where:
s
w
= Di stance between two wi res
o
=
El ectri c permi ssi vi ty constant
8 85 10
12
. x c / vm
E
o
= Corona fi el d strength
2
r
o
= Corona radi us
Versi on 10
Chapter 8
The col l ecti ng fi el d strength E
c
, i s defi ned as:
E V f
T P
TP
T P
TP r
c B
o
o
o
o o
+
_
,
1
]
1
1
0 25 0 03 . .
Where:
V
B
= Breakdown vol tage
f
= Roughness factor of wi re
T
o
= Atmospheri c temperature
P
o
= Atmospheri c pressure
T
= Temperature
P
= Pressure
The parti cl e concentrati on at the poi nt where the parti cl es fi rst have saturati on
charge, C
nvs
i s:
C
k
kd
E Ws E r
Ws E E r Ws r
nvs
c w o o
w c o o w o
+
+
0 212 2 08
0 427 2 0533
2
. ( ) .
. ( . )
Where:
k
= Di el ectri c constant ( / )
o
The parti cl e saturati on charge, q
ps
i s:
q
k d
k
E
E r
Ws
r
Ws
ps
o
c
o o
w
o
w
+
+
_
,
1
]
1
1
3
2
2
3
2 5 2
3
125
2
. .
Pressure Drop
ESP cal cul ates the pressure drop across the preci pi tator as:
p V
g g
45 5
2
.
Where:
g = Gas densi ty
V
g = Gas vel oci ty
Versi on 10
Solids
Required Power
The power requi red
2
P
w
to meet a speci fi ed separati on effi ci ency i s:
P Q
w ov
52 75 1 . ln( )
Where:
Q
= Vol umetri c gas fl ow rate
Gas Velocity
The model s used i n ESP are val i d for i nl et gas vel oci ti es rangi ng from 0.5 to 3
m/s. Outsi de thi s range, transport by turbul ent di ffusi on becomes more
si gni fi cant than by el ectrostati c force and l arge errors shoul d be expected.
Particle Diameter
You can use ESP to model the separati on of fi ne parti cl es wi th di ameters rangi ng
from 0.01 to 10 mi crons. ESP i s accurate when the i nl et parti cl e concentrati on i s
hi gh ( ). 10
11
particles / m or 0.1 kg / m
3 3
I f the concentrati on i s too l ow, the model
tends to overesti mate the separati on effi ci ency.
References
1. Crawford, M., Air Pollution Control Theory, Chapter 8: El ectrostati c
Preci pi tati on, pp. 298-358. New York: McGraw-Hi l l , 1976.
2. Whi te, H.J., I ndustrial Electrostatic Precipitation, 204, pp. 91-92 (1963).
Versi on 10
Chapter 8
HyCyc
Hydrocyclone Solids Separator
Use HyCyc to si mul ate hydrocycl ones. Hydrocycl ones separate sol i ds from the i nl et
l i qui d stream by the centri fugal force of a l i qui d vortex.
You can use HyCyc to rate or si ze hydrocycl ones. I n si mul ati on mode (rati ng),
HyCyc cal cul ates the parti cl e di ameter wi th 50% separati on effi ci ency from the
user-speci fi ed hydrocycl one di ameter. I n desi gn mode (si zi ng), HyCyc determi nes
the hydrocycl one di ameter requi red to achi eve the user-speci fi ed separati on
effi ci ency of the sol i ds wi th the desi red parti cl e si ze.
I n both cal cul ati on modes, pressure drop and the parti cl e si ze di stri buti on of the
outl et sol i ds streams are determi ned.
Flowsheet Connectivity for HyCyc
Feed
Liquid
Solids
Material Streams
Inlet One l i qui d stream wi th at l east one sol i ds substream
Outlet One stream for the cl eaned l i qui d wi th resi dual sol i ds
One stream for sol i ds
Each i nl et sol i ds substream must have a parti cl e si ze di stri buti on (PSD)
attri bute.
Versi on 10
Solids
Specifying HyCyc
Use the I nput Speci fi cati ons sheet to speci fy hydrocycl one operati ng condi ti ons.
To perform these calculations Enter HyCyc calculates
Rating Simulation Mode
Hydrocyclone Diameter
Particle diameter with 50% separation
efficiency
Pressure drop, particle size distribution of
outlet solids stream
Sizing Design Mode
Hydrocyclone diameter
Pressure drop, particle size
distribution of outlet solids stream
To obtai n practi cal di mensi ons when si zi ng hydrocycl ones, enter the:
Maxi mum di ameter of the hydrocycl one
Maxi mum pressure drop al l owed across the hydrocycl one
HyCyc desi gns mul ti pl e hydrocycl ones i n paral l el i f one of the fol l owi ng condi ti ons
exi sts:
The cal cul ated di ameter i s greater than the maxi mum speci fi ed di ameter.
The cal cul ated pressure drop i s greater than the maxi mum speci fi ed pressure
drop.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for HyCyc:
Input Specify simulation parameters, dimensions, tangential velocity correlation
parameters, and separation efficiency
Results View summary of HyCyc results and material and energy balances
Operating Ranges
HyCyc uses empi ri cal and semi -empi ri cal correl ati ons. Expect unrel i abl e resul ts
when operati ng condi ti ons (Bradl ey, D., 1965)
1
are outsi de the ranges of
experi mental data on whi ch the model s are based. I n general , your data shoul d fal l
wi thi n these ranges:
Parti cl e di ameter between and (5 to 200 mi crometers)
Hydrocycl one di ameter between 0.01 and 0.6 m
Pressure drop between 35 and 345 kPa
Separati on effi ci ency between 2% and 98%
Versi on 10
Chapter 8
The sol i ds concentrati on shoul d be l ess than 11% of the vol ume fracti on, or l ess
than 25% of the wei ght fracti on.
Separati on effi ci ency E i s defi ned as:
E
mass underflow rate of solids
mass feedflow rate of solids
Reduced effi ci ency E i s defi ned as the fracti on of feed sol i ds that go to the
underfl ow mi nus the fracti on of the feed l i qui d that al so goes to the underfl ow.

E
E R
R
f
f
1
Where R
f
i s the vol umetri c rati o of underfl ow to feed fl ow (see Materi al Spl i t ,
thi s chapter ).
The reduced effi ci ency i s obtai ned from the fol l owi ng equati on
2
:

_
,
1
]
1
1
'
E
d
d
100 1 0115
50
3
exp .
Where:
d = Di ameter of the sol i d parti cl es to be separated
d
50
= Parti cl e di ameter for whi ch 50% of feed passes through underfl ow
I n turn,
50
d i s obtai ned from the fol l owi ng equati on whi ch i ncl udes operati onal
and geometri c parameters (Bradl ey, D., 1965)
1
:
d D
D
D R
Q
c
i
n
c f
50
2
0 5
3 0 38
1
2
'
( . )
( )
( )
tan
.

Versi on 10
Solids
Where:
Q = Vol umetri c fl ow rate at i nl et
D
c
= Chamber di ameter
D
i
= I nl et di ameter
n = Power of R i n the tangenti al vel oci ty di stri buti on functi on
= I nl et vel oci ty l oss coeffi ci ent
= Densi ty of sol i d
R
f
= Underfl ow rate/feed rate
= Cone angl e
= Densi ty of l i qui d
= Vi scosi ty of l i qui d
Material Split
HyCyc spl i ts the feed accordi ng to the fol l owi ng empi ri cal correl ati on (Moder, J.M.
and Dahl strom, D.A., 1952)
3
:
S
D
D
Q
u
o
( )
. . 4 4 44
Where:
S = Vol ume spl i t = underfl ow rate/overfl ow rate
= A constant, 6.13
D
u
= Di ameter for underfl ow
D
o
= Di ameter for overfl ow
Q = I nl et vol umetri c fl ow rate (gal /mi n)
Versi on 10
Chapter 8
The fl ow rati o
f
R

(underfl ow rate/feed rate) i s then obtai ned by:
1
1
1

+
R
S
f
Tangential Velocity
The fol l owi ng empi ri cal correl ati on gi ves the tangenti al vel oci ty V (Dahl strom,
D.A., 1954)
4
i n a hydrocycl one at a radi us R:
VR constant V
D
n
i
c
n

_
,

2
Where:
= I nl et vel oci ty l oss coeffi ci ent
V
i
= I nl et vel oci ty
D
c
= Di ameter of the hydrocycl one
n = Exponent of radi al dependence
R = Radi us
For most cases, and n are determi ned experi mental l y to be 0.45 and 0.8. These
two vari abl es are then used to determi ne d
50
.
Dimension Ratios
Common hydrocycl ones have the fol l owi ng ranges of di mensi on rati os
(dimension/ chamber diameter):
Inlet diameter: 1/7 to 1/3
Length: 4 to 12
Overflow diameter: 1/8 to 1/2.3
Underflow diameter: 1/10 to 1/5
Cone angle: 9 deg. to 20 deg.
Versi on 10
Solids
Pressure Drop
For the pressure drop correl ati on to be val i d (overfl ow di ameter/underfl ow
di ameter) shoul d be 0.6 to 2.0. HyCyc uses the empi ri cal pressure drop
correl ati on (Dahl strom, D.A., 1954)
4
:
Q
H
D D
o i 0 5
0 9
6 38
.
.
. ( )
Where:
Q = Vol umetri c fl ow rate (US gal l ons/mi nute) at the i nl et
H = Hei ght of fl ui d (feet) or l ength of vortex fi nder
D
o
= Overfl ow di ameter
D
i
= I nl et di ameter
Hydrocyclone Dimensions
The next fi gure shows the HyCyc geometry.
Inlet D
i
L
D
o
D
c
D
u
Hydrocyclone Dimensions
Versi on 10
Chapter 8
The fol l owi ng tabl e descri bes the HyCyc di mensi ons.
Term Description
D
c
Chamber diameter
D
i
Inlet diameter
D
o
Overflow diameter
D
u
Underflow diameter
L Length of hydrocyclone
Cone angle
References
1. Bradl ey, D., The Hydrocyclone, 1
st
edi ti on., Pergamon Press, London (1965).
2. Yoshi oka, H. and Hatta, Y., Kagaku Kagol ar, Chemical Engineering, Japan,
19, 633 (1955).
3. Moder, J.M. and Dahl strom, D.A., Chemical Engineering Progress, 48,75
(1952).
4. Dahl strom, D.A., Mi neral Engi neeri ng Techni ques, Chemical Engineering
Progress Symposium Series 50, No. 15, 41 (1954).
Versi on 10
Solids
CFuge
Centrifuge Filter
Use CFuge to si mul ate centri fuge fi l ters. The centri fuge fi l ters separate l i qui ds
and sol i ds by the centri fugal force of a rotati ng basket.
Use CFuge to rate or si ze centri fuge fi l ters.
CFuge assumes that the separati on effi ci ency of the sol i ds equal s 1, so that the
outl et fi l trate stream contai ns no resi dual sol i ds.
Flowsheet Connectivity for CFuge
Feed
Liquid
Solids
Material Streams
Outlet One materi al stream for the l i qui d
I f you speci fy the parti cl e si ze di stri buti on (PSD), CFuge cal cul ates the average
parti cl e si ze.
Versi on 10
Chapter 8
Specifying CFuge
Use the I nput Speci fi cati ons sheet to speci fy operati ng condi ti ons and the I nput
Fi l terCake sheet to speci fy fi l ter cake properti es.
To perform these
calculations Enter CFuge calculates
Rating Diameter
Rate of revolution
Filter cake properties
Filtrate flow rate
Filter cake moisture content
Height of centrifuge basket
Sizing List of centrifuge diameters and rates
of revolution
Filter cake moisture content (CFuge
estimates if not entered)
Filtrate flow rate
Filter cake moisture content
Height of centrifuge basket
For si zi ng cal cul ati ons, CFuge al so cal cul ates the l i qui d-handl i ng capaci ti es of al l
of the centri fuges you speci fy. CFuge sel ects the centri fuge wi th a l i qui d-handl i ng
capaci ty greater than or equal to the requi red fi l trate fl ow rate. I f more than one
centri fuge sati sfi es thi s cri teri on, CFuge sel ects the one wi th the smal l est
capaci ty. I f none of the centri fuges sati sfi es thi s cri teri on, CFuge sel ects the one
wi th the hi ghest fi l trate fl ow rate.
I n both rati ng and si zi ng cal cul ati ons, CFuge cal cul ates the content and hei ght of
the centri fuge basket.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for CFuge:
Input Specify centrifuge and filter cake parameters and centrifuge dimensions
Results View summary of CFuge results and material and energy balances
Filter Cake Characteristics
Use the I nput Fi l terCake sheet to speci fy:
Cake resi stance
Moi sture Content
Spheri ci ty
Medi um resi stance
Porosi ty
The average di ameter of the sol i d parti cl es i n the cake
Versi on 10
Solids
The fi l ter cake moi sture content i s the rati o of the mass fl ow rate of l i qui d to that
of the sol i d i n the outl et sol i ds stream. The fi l ter cake moi sture content i s an
i mportant desi gn parameter. You shoul d provi de i t i f possi bl e. I f you do not enter
i t, CFuge cal cul ates an esti mate from the average parti cl e di ameter and cake
parameters (Dombrowski , H.S., and Brownel l , L.E., 1954)
1
.
I f you enter the parti cl e si ze di stri buti on (PSD) of the i nl et sol i d stream, CFuge
cal cul ates the average parti cl e di ameter, so you do not need to enter average
di ameter on the I nput Fi l terCake sheet.
Filtrate Flow Rate
CFuge cal cul ates the fi l trate vol umetri c fl ow rate from:
Q F WM
l

1
( )
Where:
F = Feed l i qui d vol umetri c fl ow rate
M = Moi sture content, mass of l i qui d/mass of dri ed sol i d
(speci fi ed as Moi sture Content on the Fi l terCake sheet or
cal cul ated by the model )
W = Dry sol i ds feed rate
l
= Li qui d densi ty
Pressure Drop
CFuge cal cul ates the pressure drop (Grace, H.P., 1953)
2
across the fi l ter cake as:
p
r r
l

2
2
2
1
2
2
( )
Where:
= Rotati onal speed
r
1
= Radi us of l i qui d surface
r
2
= Radi us of i nner wal l of bowl
l
= Li qui d densi ty
Versi on 10
Chapter 8
Separati on effi ci ency, E, i s defi ned as:
E
underflow rate of solids
feedflow rate of solids
CFuge assumes that the separati on effi ci ency of the sol i ds equal s 1, so that the
outl et fi l trate stream contai ns no resi dual sol i ds.
References
1. Dombrowski , H.S., and Brownel l , L.E., I ndustrial and Engineering
Chemistry, 46, 6, 1207 (1954).
2. Grace, H.P., Chemical Engineering Progress, 49, 8, 427 (1953).
Versi on 10
Solids
Filter
Rotary Vacuum Filter
Use Fi l ter to si mul ate conti nuous rotary vacuum fi l ters. You can use Fi l ter to
rate or si ze rotary vacuum fi l ters.
Fi l ter assumes the separati on effi ci ency of the sol i ds equal s 1, so that the outl et
fi l trate stream contai ns no resi dual sol i ds.
Flowsheet Configuration for Filter
Feed
Filtrate
Solids
Material Streams
Outlet One materi al stream for the l i qui d fi l trate
Specifying Filter
Use the I nput Speci fi cati ons sheet to speci fy operati ng condi ti ons and
parameters.
Versi on 10
Chapter 8
To perform these
calculations Enter Filter calculates
Rating Simulation
Diameter
Width
Rate of revolution
Filter cake characteristics (optional)
Pressure drop
across filter
Sizing Design
Maximum allowable pressure drop across the filter cake and
medium
Rate of revolution
Filter cake characteristics (optional)
Width to diameter ratio (optional)
Diameter
Width
I n both cal cul ati on modes, ASPEN PLUS determi nes the fol l owi ng:
Fi l trate vol umetri c fl ow rate
Cake thi ckness
Mass fracti on of sol i ds i n the sol i ds fi l ter cake
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Fi l ter:
Input Specify filter and filter cake parameters
Results View summary of Filter results and material and energy balances
Filter Cake Characteristics
Fi l ter assumes:
The cake thi ckness i s greater than 0.00635 m.
The capi l l ary number i s greater than 1.
The fi l ter cake i s i ncompressi bl e or compacted uni forml y throughout i ts
thi ckness
2
When the speci fi c cake resi stance at the requi red pressure drop P i s not
avai l abl e, Fi l ter can esti mate i t usi ng the fol l owi ng empi ri cal correl ati on:
( )
O
k
P
Where:
O = Speci fi c cake resi stance at uni t pressure drop

k
= Cake compressi bi l i ty
Versi on 10
Solids
You can use thi s equati on for i nterpol ati on and short-range extrapol ati on when
some experi mental data of
O
and P are avai l abl e.
O
i s the i ntercept of the
l og-l og pl ot of versus P. and
O
both have the uni ts determi ned by the
speci fi ed uni ts set, and P i s al ways i n Pascal s.
Use the Average Di ameter fi el d on the Fi l terCake sheet to speci fy the average
di ameter of sol i d parti cl es i n the fi l ter cake. I f you enter the parti cl e si ze
di stri buti on (PSD) of the i nl et sol i d stream, Fi l ter cal cul ates the average parti cl e
si ze.
Pressure Drop
Fi l ter cal cul ates the pressure drop
1
across the fi l ter cake wi th:
Q RHV RH
p V
W

1
]
1
2
1 2
/
Where:
Q = Fi l trate vol ume fl ow rate
= Angul ar vel oci ty
R = Radi us
H = Wi dth
V = Fi l trate vol ume per uni t area
p = Pressure drop
= Wetti ng angl e
= Vi scosi ty
= Fi l trati on resi stance
W = Sol i d mass per uni t area
Separati on effi ci ency, E, i s defi ned as:
E
underflow rate of solids
feedflow rate of solids

Versi on 10
Chapter 8
Fi l ter assumes the separati on effi ci ency of the sol i ds equal s 1, so that the outl et
fi l trate stream contai ns no resi dual sol i ds.
References
1. Brownel l , L.E. and Katz, D. I ., Chemical Engineering Progress, 43, 11, 601
(1947).
2. Dombrowski , H.S. and Brownel l , L.E., I ndustrial and Engineering Chemistry,
46, 6, 1207 (1954).
Additional Reading:
Brownel l , L.E. and Katz, D. I ., Chemical Engineering Progress, 43, 10, 537
(1947).
Dahl strom, D.A. and Si l verbl att, C.E., Solid/ Liquid Separation Equipment Scale
Up, Chapter 2, Purchas, D.B., Ed., Upl ands Press Ltd. (1977).
Si l verbl att, C.E., Ri sbud, H., and Ti l l er, F.M., Chemical Engineering, 127 (Apri l
27, 1974).
Versi on 10
Solids
Versi on 10
Chapter 8
SWash
Single-Stage Solids Washer
Use SWash to si mul ate sol i ds washers i n whi ch di ssol ved components i n the
entrai ned l i qui d of a sol i ds stream are recovered by a washi ng l i qui d. SWash
si mul ates a si ngl e-stage sol i ds washer; i t does not consi der the presence of a
vapor phase.
SWash cal cul ates the fl ow rates and composi ti ons of the outl et sol i ds and l i qui d
streams from a user-speci fi ed l i qui d-to-sol i d mass rati o of the outl et sol i ds
stream and the mi xi ng effi ci ency of the washer. For non-adi abati c operati ons,
SWash determi nes the outl et temperature when outl et pressure and heat duty
are gi ven. Al ternati vel y, SWash cal cul ates the requi red heat duty when outl et
temperature and pressure are speci fi ed.
Flowsheet Connectivity for SWash
Liquid
Solids
Liquid
Solids
Heat (optional) Heat (optional)
Material Streams
Inlet One stream for the sol i ds parti cl es wi th an entrai ned l i qui d
One stream for the washi ng l i qui d
Outlet One stream for the washed sol i ds parti cl es
One stream for the washi ng l i qui d and entrai ned l i qui d from the i nl et
sol i ds stream
Heat Streams
Inlet One stream for heat duty (opti onal )
Outlet One stream for net heat duty (opti onal )
Versi on 10
Solids
I f you speci fy onl y pressure on the I nput Outl etFl ash sheet, SWash uses the i nl et
heat stream as a duty speci fi cati on. Otherwi se, SWash onl y uses the i nl et heat
stream to cal cul ate the net heat duty. The net heat duty i s the i nl et heat stream
mi nus the actual (cal cul ated) heat duty.
Specifying SWash
You must speci fy the mi xi ng effi ci ency of the washer and the l i qui d-to-sol i d mass
rati o of the outl et sol i ds stream. For non-adi abati c operati ons, you must speci fy
the pressure of the washer and one of the fol l owi ng:
The temperature of the washer
Heat duty (or an i nl et heat stream wi thout an outl et heat stream)
Al ternati vel y, SWash cal cul ates the requi red heat duty when outl et temperature
and pressure are speci fi ed.
SWash assumes adi abati c operati ons i f nei ther temperature nor heat duty i s
speci fi ed.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for SWash:
Input Specify operating parameters, flash specifications, and convergence parameters
Results View summary of SWash results and material and energy balances
Mixing Efficiency
The mi xi ng effi ci ency of the washer, E, i s defi ned as:
E
x x
x x
IN
S
OUT
S
IN
S
OUT
L
Where:
x
IN
S
= Mass fracti on of di ssol ved components i n the entrai ned
l i qui d of the i nl et sol i ds stream
x
OUT
S
= Mass fracti on of di ssol ved components i n the entrai ned
l i qui d of the outl et sol i ds stream
x
OUT
L
= Mass fracti on of di ssol ved components i n the outl et l i qui d
stream
Versi on 10
Chapter 8
Bypass Fraction
The bypass fracti on i s the fracti on of l i qui d i n the feed that bypasses the mi xi ng,
when mi xi ng effi ci ency i s l ess than 1. I t i s cal cul ated as:
Bypass fraction mixing efficiency
liquid to solid ratio specified for SWash
liquid to solid ratio in inlet solids stream

( ) 1
Versi on 10
Solids
CCD
Counter-Current Decanter
CCD si mul ates a counter-current decanter or a mul ti stage washer. CCD
cal cul ates the outl et fl ow rates and composi ti ons from:
Mi xi ng effi ci ency
Li qui d-to-sol i d mass rati o of each stage
CCD can cal cul ate:
The heat duty profi l e from a speci fi ed temperature profi l e
The temperature profi l e from a speci fi ed heat duty profi l e
CCD does not consi der a vapor phase.
Flowsheet Connectivity for CCD
Overflow Solids
(Top feed)
Product From
Overflow
(optional)
Feed To
Overflow
(optional)
Washing
Liquid
(Bottom feed)
Underflow
Product From
Underflow
(optional)
Feed To
Underflow
(optional)
Nstage
1
Material Streams
Inlet One sol i ds i nl et materi al stream (top feed)
One l i qui d i nl et materi al stream (bottom feed)
Any number of opti onal i nl et materi al si de streams per stage
Outlet One top product stream (overfl ow)
One bottom product stream (underfl ow)
One opti onal stream per stage for the sol i ds (underfl ow)
One opti onal stream per stage for the l i qui d (overfl ow)
Versi on 10
Chapter 8
Any number of pseudoproduct streams can represent i nternal underfl ows or
overfl ows. A pseudoproduct stream does not affect the resul ts of the si mul ati on.
Specifying CCD
Use the CCD I nput Speci fi cati ons sheet to enter the number of stages, pressure,
mi xi ng effi ci ency, and l i qui d-to-sol i d mass rati o.
Use the CCD I nput Streams to enter feed, product, and opti onal heat stream
l ocati ons.
On the CCD I nput Temp-DutyProfi l es sheet, note the fol l owi ng:
If you enter CCD calculates
Stage temperature Stage heat duty
Stage heat duty Stage temperature
Stage overall heat transfer
coefficient
Stage temperature
You cannot enter both temperature profi l es and heat duti es or overal l heat
transfer coeffi ci ents. I f you enter stage heat duty and/or an overal l heat transfer
coeffi ci ent, and you do not enter val ues for al l stages, the system assumes
unspeci fi ed val ues to be zero. Enter the medi um temperature of each stage when
you enter overal l heat transfer coeffi ci ents. Use the Esti mated Temperature fi el d
to enter esti mated stage temperatures.
Note CCD i nterpol ates unspeci fi ed val ues and, by defaul t, assumes
them to be the same as the ambi ent temperature.
Use the CCD I nput PseudoStream sheet to transfer the i nternal overfl ow or
underfl ow of a stage to a pseudostream.
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for CCD:
Input Specify operating parameters, temperature profile parameters,
pseudostream information, and convergence parameters
Results View summary of CCD results, material and energy balances, and stage
profiles
Versi on 10
Solids
CCD does not consi der the mi xi ng of component attri butes and PSDs. CCD
assumes al l outl et sol i ds streams have the same attri butes and PSD as the sol i ds
feed stream to stage one. CCD al so assumes al l outl et l i qui d streams have the
same attri butes and PSD as the l i qui d feed stream throughout the fi nal stages.
Multistage Washer Profiles
For any CCD profi l e, such as mi xi ng effi ci ency, l i qui d-to-sol i d-rati o, temperature,
duty, enter a val ue for every stage, as i nformati on becomes avai l abl e. I f you enter
onl y some of the val ues for some stages, CCD generates the compl ete profi l e by
l i near i nterpol ati on of the gi ven val ues. I f you enter onl y one val ue, CCD
assumes a constant profi l e of that val ue throughout the washer.
Mixing Efficiency
The mi xi ng effi ci ency of stage n i s defi ned as:
E
x x
x x
IN
S
OUT
S
IN
S
OUT
L
Where:
x
IN
S
= Mass fracti on of di ssol ved components i n the entrai ned l i qui d of the
total i nl et sol i ds stream to stage n.
x
OUT
S
= Mass fracti on of di ssol ved components i n the entrai ned l i qui d of the
total outl et sol i ds stream from stage n.
x
OUT
L
= Mass fracti on of di ssol ved components i n the outl et l i qui d stream
from stage n.
Versi on 10
Chapter 8
Medium Temperature
The duty for each stage i s cal cul ated accordi ng to the fol l owi ng equati ons:
Q UA Tcalc Tmed
i i i i
( )
Where:
Q
i
= Heat duty for stage i
UA
i
= Product of heat transfer coeffi ci ent and area for stage i
Tcalc
i
= Cal cul ated outl et temperature of stage i
Tmed
i
= Temperature of the heat transfer medi um at stage i
O O O O
Versi on 10
Solids
Versi on 10
Chapter 9
9 User Models
Thi s chapter descri bes the model s that al l ow you to wri te your own uni t
operati on model s as Fortran subrouti nes. These subrouti nes must fol l ow the
gui del i nes descri bed i n the ASPEN PLUS User Models reference manual . The
model s are:
User User-defined unit operation
model
Model a unit operation using a user-supplied
Fortran subroutine
Unit operations with four (or
fewer) inlet and outlet
streams
User2 User-defined unit operation
model
Model a unit operation using a user-supplied
Fortran subroutine.
Unit operations with no limit
on number of streams
Versi on 10
User Models
User
User-Supplied Unit Operation Model
User can model any uni t operati on model . You must wri te a Fortran subrouti ne
to cal cul ate the val ues of the outl et streams based on the i nl et streams and
parameters you speci fy.
User and User2 di ffer onl y i n the number of i nl et and outl et streams al l owed and
the argument l i sts to the model subrouti ne. User i s l i mi ted to a maxi mum of four
materi al and one heat or work i nl et stream and a maxi mum of four materi al and
one heat or work outl et stream. User2 has no l i mi ts on the number of i nl et and
outl et streams.
Flowsheet Connectivity for User
Heat (optional)
Work (optional)
Heat (optional)
Material
Work (optional)
Material Streams
Inlet One to four i nl et materi al streams
Outlet One to four outl et materi al streams
Heat Streams
Inlet One heat stream (opti onal )
Work Streams
Inlet One work stream (opti onal )
Outlet One work stream (opti onal )
Versi on 10
Chapter 9
Specifying User
You must speci fy the name of the subrouti ne model on the I nput Speci fi cati ons
sheet. You have the opti on of speci fyi ng:
A report subrouti ne name
Si ze of the i nteger and real arrays (I NT and REAL) passed to the user model
subrouti ne
Val ues of the i nteger and real arrays passed to the user model subrouti ne
Length of i nteger and real workspace vectors
Thermodynami c condi ti ons of each outl et stream
Type of fl ash cal cul ati ons (vapor, l i qui d, two-phase, three-phase)
For i nformati on on wri ti ng Fortran subrouti nes for user model s, see the
ASPEN PLUS User Models reference manual .
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for User:
Input Specify name and parameters for user subroutine, calculation options, and
outlet stream conditions and flash convergence parameters
Results View summary of User results and material and energy balances
Versi on 10
User Models
User2
User-Supplied Unit Operation Model
User2 can model any uni t operati on model . You must wri te a Fortran subrouti ne
to cal cul ate the val ues of the outl et streams based on the i nl et streams and
parameters you speci fy.
User and User2 di ffer onl y i n the number of i nl et and outl et streams al l owed and
the argument l i sts to the model subrouti ne. User2 has no l i mi ts on the number of
i nl et and outl et streams. User i s l i mi ted to a maxi mum of four materi al and one
heat or work i nl et stream, and a maxi mum of four materi al and one heat or work
outl et stream.
Flowsheet Connectivity for User2
Heat (optional)
Work (optional)
Heat (optional)
Material
Work (optional)
Material Streams
Outlet At l east one outl et materi al stream
Heat Streams
Outlet Any number of heat streams (opti onal )
Work Streams
Outlet Any number of work streams (opti onal )
Versi on 10
Chapter 9
Specifying User2
You must speci fy the name of the subrouti ne model on the User2 I nput
Speci fi cati ons sheet. You have the opti on of speci fyi ng:
A report subrouti ne name
Si ze of the i nteger and real arrays (I NT and REAL) passed to the user model
subrouti ne
Val ues of the i nteger and real arrays passed to the user model subrouti ne
Length of i nteger and real workspace vectors
Thermodynami c condi ti ons of each outl et stream
Type of fl ash cal cul ati ons (vapor, l i qui d, two-phase, three-phase)
For i nformati on on wri ti ng Fortran subrouti nes for user model s, see ASPEN
PLUS User Models reference manual .
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for User2:
Input Specify name and parameters for user subroutine, calculation options, and outlet
stream conditions and flash convergence parameters
Results View summary of User2 results and material and energy balances
O O O O
Versi on 10
User Models
Versi on 10
Chapter 10
10 Pressure Relief
Thi s chapter contai ns detai l ed reference i nformati on on the ASPEN PLUS
Pres-Rel i ef model for pressure rel i ef cal cul ati ons. For i nformati on on usi ng
Pres-Rel i ef, see the ASPEN PLUS User Guide, Chapter 33.
Thi s chapter descri bes the fol l owi ng topi cs:
Speci fyi ng Pres-Rel i ef
Scenari os
Rul es to si ze the rel i ef val ve pi pi ng
Compl i ance wi th codes
Stream and vessel composi ti ons and condi ti ons
Reacti ons
Rel i ef system
Data tabl es for pi pes and rel i ef devi ces
Val ve cycl i ng
Vessel types
Di sengagement model s
Stop cri teri a
Sol uti on procedure for dynami c scenari os
Fl ow equati ons
Cal cul ati on and convergence methods
Vessel i nsul ati on credi t factor
Versi on 10
Pressure
Relief
Pres-Relief
Pressure Relief Model
Use Pres-Rel i ef to do ei ther of the fol l owi ng:
Determi ne the steady-state fl ow rati ng of pressure rel i ef systems
Dynami cal l y model vessel s undergoi ng pressure rel i ef due to a fi re or heat
i nput speci fi ed by the user. You may speci fy that reacti ons occur i n the vessel .
Specifying Pres-Relief
Use Pres-Rel i ef to do ei ther of the fol l owi ng:
Determi ne the steady-state fl ow rati ng of pressure rel i ef systems
Dynami cal l y model vessel s undergoi ng pressure rel i ef due to a fi re or heat
i nput speci fi ed by the user. You may speci fy that reacti ons occur i n the vessel
Use the Setup form to speci fy the pressure rel i ef scenari o, general speci fi cati ons
such as the di scharge pressure and the esti mated fl ow rate, i nl et stream
condi ti ons, i ni ti al vessel condi ti ons, desi gn rul es, and any reacti ons (dynami c
scenari os onl y) that occur.
Use the Rel i ef Devi ce form to speci fy the rel i ef system. You must sel ect a rel i ef
devi ce and speci fy i ts characteri sti cs. You must al so speci fy the vessel neck and
the number of i nl et and tai l pi pe secti ons to be used.
Use the Dynami c I nput form to speci fy the requi red parameters for dynami c
scenari os. These i ncl ude vessel speci fi cati ons, di sengagement model s and detai l s
speci fi c to the chosen scenari o. For the fi re scenari o, you must speci fy the fi re
standard and the credi ts to be used. When the scenari o i s Dynami c run wi th
speci fi ed heat fl ux, you must speci fy the heat i nput parameters.
When the number of i nl et and tai l pi pe secti ons exceeds 0, you must speci fy the
detai l s for each secti on i n the I nl et Pi pes and Tai l Pi pes forms.
For dynami c scenari os, use the Operati ons form to speci fy one or more vari abl es
to be used as stop cri teri a. The si mul ati on wi l l stop when the val ue of any of
these vari abl es exceeds the user-speci fi ed l i mi t.
Versi on 10
Chapter 10
Use the fol l owi ng forms to enter speci fi cati ons and vi ew resul ts for Pres-Rel i ef:
Setup Specify pressure relief scenario, general specifications, initial stream conditions, design
rules, and any reactions that occur (required input)
Relief Device Specify the type of relief device and the characteristics of the device (required input)
Inlet Pipes Specify piping, fittings, and valves immediately upstream of the relief device (optional
input)
Tail Pipes Specify piping, fittings, and valves immediately downstream of the relief device (optional
input)
Dynamic Input Specify parameters describing the dynamic event (required for dynamic scenarios)
Operations Specify criteria that will terminate the dynamic simulation (required for dynamic
scenarios)
Convergence Override default methods and convergence parameters for the algorithms involved in the
pressure relief simulation (optional input)
Block Options Override default methods and options for property calculation, simulation, diagnostics,
and reporting (optional input)
Results Review calculated results and profiles for the steady-state scenarios
Dynamic Results Review calculated results and profiles for the dynamic scenarios
Scenarios
Scenari os are si tuati ons that cause venti ng through the pressure rel i ef system to
occur. Pres-Rel i ef supports the fol l owi ng scenari os:
Dynami c run wi th vessel engul fed by fi re
Dynami c run wi th speci fi ed heat fl ux i nto vessel
Steady state fl ow rati ng of rel i ef system
Steady state fl ow rati ng of rel i ef val ve
Dynamic Run with Vessel Engulfed by Fire
Use thi s scenari o to model a vessel engul fed by fi re. You must speci fy the vessel
geometry and i ni ti al composi ti on. ASPEN PLUS can compute the energy i nput
for thi s scenari o accordi ng to the fol l owi ng standards:
NFPA-30
API -520
API -2000
Versi on 10
Pressure
Relief
ASPEN PLUS assumes the cal cul ated energy i nput i s constant duri ng the enti re
venti ng transi ent. ASPEN PLUS uses credi t factors for drai nage, water-spray,
fi re-fi ghti ng equi pment, and i nsul ati on to reduce energy i nput, i f appropri ate for
the chosen standard. You may speci fy a total credi t factor i nstead of i ndi vi dual
credi t factors. You must speci fy the fi re durati on ti me. Thi s i s a dynami c
scenari o. The vessel contents and rel i ef rate change as a functi on of ti me.
The fol l owi ng tabl es descri be how ASPEN PLUS cal cul ates wetted area, energy
i nput, and credi t factors for each of the three standards.
Calculation of Wetted Area
Vessel type NFPA-30 API-2000 API-520
Horizontal 75% of total exposed
area
75% of total area or area to a height of
30 ft. above grade, whichever is greater
Wetted area up to 25 ft. above grade
(based on specified liquid level)
Vertical Area up to 30 ft.
above grade. Bottom
plate is included if
exposed
Area up to 30 ft. above grade. If on
ground, bottom plate is not included.
Wetted area up to 25 ft above grade
(based on specified liquid level).
Bottom plate is included if exposed.
Sphere 55% of total exposed
area
55% of surface area, or surface area to
a height 30 ft. above grade, whichever
is greater
Up to a maximum horizontal diameter
or up to height of 25 ft. above grade,
whichever is greater
Calculation of Q (Btu/hr), Based on Area (sq-ft)
NFPA-30
and API-2000
Area range Heat input
20 < area < 200 Q=20,000Area
200 < area < 1000 Q=199,300(Area
0.566
)
1000 < area < 2800 Q=963,400(Area
0.338
)
2800 < area Q=21000(Area
0.82
)
For NFPA-30 , QMAX=14,090,000 at 2800 square feet if operating pressure <1 PSI G
API-520
Heat input
Q=34,500(Area
0.82
)
Versi on 10
Chapter 10
Calculation of Credit Factors
Type NFPA-30 API-2000 API-520
Insulation only .3 F=K(1660-TF)/21,000t
You must specify F

Same as API-2000
Drainage only .5
(Area > 200 sq. ft.)
1. Not defined
Water and drainage .3 1. Not defined
Water, insulation, and
drainage
.15
NSUL Not defined
Insulation and drainage .15
Not defined Not defined
Drainage and prompt fire
fighting effort
No credit Not defined 0.6*INSUL
Portable No credit factors allowed Not defined Not defined
See Vessel I nsulation Credit Factor, this chapter.

Dynamic Run with Specified Heat Flux into Vessel
Thi s scenari o i s si mi l ar to the fi re exposure scenari o, except i t can model any
energy i nput. ASPEN PLUS can compute the energy i nput for thi s scenari o i n
three ways dependi ng on whether you speci fy:
A constant duty
A duty profi l e
An area for heat transfer, a heat transfer coeffi ci ent, and a source fl ui d
temperature
Thi s scenari o i s a dynami c scenari o and i s typi cal l y used for el ectri cal heaters
and other energy sources.
Steady State Flow Rating of Relief System
Use thi s scenari o to fi nd the fl ow rate through a speci fi ed rel i ef system at the
speci fi ed composi ti on. For thi s scenari o, you must enter your own:
Rel i ef rate
Pi pi ng descri pti on
Feed stream composi ti on
Feed stream condi ti on
Versi on 10
Pressure
Relief
Steady State Flow Rating of Relief Valve
Use thi s scenari o to fi nd the fl ow rate through a val ve, gi ven the composi ti on and
condi ti on at the entrance to the val ve. Thi s i s the si mpl est scenari o. I t i s si mi l ar
to the steady state fl ow rati ng of rel i ef system scenari o, except no pi pi ng i s
al l owed.
Compliance with Codes
Pres-Rel i ef al l ows two types of runs:
Code capaci ty
Actual capaci ty
The pri mary purpose of the code capaci ty run i s to ensure that the capaci ty of the
rel i ef system, rated as requi red by code, exceeds the maxi mum capaci ty di ctated
by the scenari o. The maxi mum pressure reached duri ng the rel i ef event must be
l ess than the code al l owabl e accumul ati on. The Code Capaci ty run i ncl udes the:
ASME val ve rati ng factor of .90
Val ve fl ow coeffi ci ent
A combi nati on coeffi ci ent
The combi nati on coeffi ci ent i s onl y i ncl uded i f a rupture di sk/rel i ef val ve
combi nati on i s bei ng desi gned. Typi cal combi nati on coeffi ci ents for NBBI
certi fi ed combi nati ons are cl ose to 1.00. I f the combi nati on i s not certi fi ed, the
ASME code requi res a combi nati on coeffi ci ent of .90. The pri mary purpose of the
actual capaci ty run i s to provi de the best esti mate of the actual fl ow through the
system. Desi gn of downstream equi pment (other than the tai l pi pe) i s one
exampl e why you mi ght need thi s i nformati on. The actual capaci ty run contai ns
the val ve fl ow coeffi ci ent, but not the ASME val ve rati ng factor of .90 or the
combi nati on coeffi ci ent.
Stream and Vessel Compositions and Conditions
For the steady-state scenari os, you must speci fy the composi ti on and condi ti ons
(two of temperature, pressure, and vapor fracti on) of the feed stream. You can do
thi s on the Setup Streams sheet i n two ways:
Reference an ASPEN PLUS stream
Gi ve the composi ti on and condi ti ons of the stream as i nput to Pres-Rel i ef
Versi on 10
Chapter 10
For the dynami c scenari os, you must speci fy the composi ti on and the condi ti ons
i n the vessel at the begi nni ng of the pressure rel i ef cal cul ati ons. Do thi s by
referenci ng an ASPEN PLUS stream, or by speci fyi ng the composi ti on and two of
temperature, pressure, and vapor fracti on on the Setup Vessel Contents sheet.
As wi th the steady-state scenari os, you may reference an ASPEN PLUS stream
or gi ve the composi ti on and condi ti ons as i nput to Pres-Rel i ef. When vapor
fracti on i s not speci fi ed, you may al so speci fy:
I ni ti al l i qui d fi l l fracti on (fi l l age) of the vessel
Pad-gas pressure and Component I D
Onl y two of temperature, pressure, and vapor fracti on can be speci fi ed or
referenced from a stream.
Rules to Size the Relief Valve Piping
ASPEN PLUS uses several rul es (3% rul e, X% rul e, and 97% rul e) to si ze the
i nl et and outl et pi pi ng wi th PSVs. The rul es use the fol l owi ng termi nol ogy:
DSP = Di fferenti al set pressure
CBP = Constant back pressure
Psta = Stati c pressure
Ptot = Stati c pressure + vel oci ty pressure
I DP = I nl et pressure drop
Ptot (vessel ) - Ptot (val ve i n)
BBP = Bui l t-up back pressure
Psta (val ve out) - CBP
These rul es are appl i ed for both actual and code capaci ty runs and are appl i ed at
the converged sol uti on for the steady-state scenari os.
For dynami c scenari os, the 3% Rul e and X% Rul e are appl i ed once, at 10%
overpressure. I f al l pressures are above 10% overpressure, the test i s not
performed and a warni ng i s i ssued. I f al l pressures are bel ow 10% overpressure,
the hi ghest pressure val ue i s scal ed up to 10% overpressure, and the scal ed
val ues are used i n appl yi ng the rul e. The 97% rul e i s appl i ed when the pressure
at the val ve i nl et i s at or above 10% overpressure.
None of the requi red standards menti ons any of these rul es except for the X%
rul e wi th X=10. The X% rul e i s menti oned i n the non-mandatory appendi x of the
ASME code.
Versi on 10
Pressure
Relief
3% Rule
Accordi ng to the 3% rul e, the total pressure l oss i n the i nl et must be l ess than 3%
of the di fferenti al set pressure when the fl ow rate i s equal to the code capaci ty of
the val ve at 10% overpressure.
IDP DSP 0 03 .
For cases where the overpressure does not reach 10%, adjust the pressure drop
rul e by mul ti pl yi ng by the rati o of the maxi mum fl owi ng pressure to 10%
overpressure (psi g).
IDP
RP
SP
0 03
11
.
.
X% Rule
Accordi ng to the X% rul e, the bui l t-up back pressure must be l ess than X% of the
di fferenti al set pressure when the fl ow rate i s equal to the code capaci ty of the
val ve at 10% overpressure.
BBP
X
DSP
100
For cases where the overpressure does not reach 10% adjust the pressure drop
rul e by mul ti pl yi ng by the square of the rati o of the maxi mum fl owi ng pressure
to 10% overpressure (psi g).
BBP
X RP
PS
_
,
100 11
2
.
97% Rule
Accordi ng to the 97% rul e, 97% of the di fferenti al set pressure must be avai l abl e
across the val ve anyti me the over pressure i s equal to or above 10% wi th a fl ow
through the val ve based on code capaci ty.
RP CBP IDP BBP DSP 0 97 .
For cases where the overpressure does not reach 10%, appl y the rul e at peak
overpressure.
Versi on 10
Chapter 10
Recommendations for Specific Valve Types
For standard spri ng l oaded val ves or pop acti on pi l ot val ves wi th
unbal anced pi l ots vented to the di scharge:
The di fferenti al set pressure i s the set pressure mi nus the constant back
pressure.
DSP SP CBP
Si ze the i nl et pi pi ng usi ng the 3% rul e.
Si ze the outl et pi pi ng usi ng the 97% rul e.
-Or-
Si ze the outl et pi pi ng wi th the X% rul e usi ng X = 10.
For bal anced bel l ows spri ng l oaded val ves:
The di fferenti al set pressure i s the set pressure.
DSP SP
Si ze the i nl et pi pi ng usi ng the 3% rul e.
For modul ati ng pi l ot operated val ves wi th bal anced pi l ots or pi l ots
vented to atmosphere:
The di fferenti al set pressure i s the set pressure.
DSP SP
You can use the scenari o requi red fl ow rather than the val ve capaci ty for
pressure drop cal cul ati ons as an opti on. Thi s can easi l y be si mul ated by changi ng
the i nput ori fi ce area unti l the overpressure reaches 10%.
There i s no i nl et pressure drop rul e.
Reactions
I f the protected vessel i s a verti cal , hori zontal , API , spheri cal , or user-speci fi ed
tank, you may model i t wi th or wi thout reacti ons. Speci fy the reacti ons by gi vi ng
the Reacti ons I D on the Setup Reacti ons sheet.
Versi on 10
Pressure
Relief
Relief System
The venti ng system consi sts of:
A vessel neck
One or two secti ons of i nl et pi pe
The rel i ef devi ce i tsel f
One or two secti ons of tai l pi pe
I n a si mul ati on, the system bei ng model ed may consi st of an i nl et pi pe wi thout a
rel i ef devi ce, or a rel i ef devi ce connected to the vessel wi thout an i nl et pi pe. The
tai l pi pe i s opti onal .
Relief Devices
Pres-Rel i ef can model the fol l owi ng types of rel i ef devi ces:
Safety rel i ef val ves (PSVs; both l i qui d and gas/2-phase)
Rupture di sks (PSDs)
Emergency rel i ef val ves (ERVs)
SRV/rupture di sk combi nati ons
Open vent pi pes
I nternal tabl es (accessed from the Rel i efDevi ce SafetyVal ve sheet) contai n
several standard commerci al l y avai l abl e val ves, al ong wi th al l the mechani cal
speci fi cati ons and certi fi ed coeffi ci ents needed i n the rel i ef cal cul ati ons. You may
choose one val ve from the tabl es, or enter your own val ve speci fi cati ons and
coeffi ci ents.
For l i qui d servi ce val ves, you must al so speci fy the ful l -l i ft overpressure. Thi s
al l ows ASPEN PLUS to si mul ate some of the ol der styl e val ves whi ch do not
achi eve ful l l i ft unti l 25% overpressure i s reached.
For gas/2-phase servi ce val ves, you must al so speci fy the average openi ng and
cl osi ng factors. The val ve does not open unti l the pressure drop across the val ve
reaches (openi ng factor * Di f-Setp). The val ve cl oses when the pressure drop
across i t reaches (cl osi ng factor * Di f-Setp).
I n an actual capaci ty run, the rupture di sk i s model ed as a bi t of resi stance usi ng
the pi pe model . The defaul t val ue of L/D i s 8 for a rupture di sk wi th a di ameter
of 2 i nches or l ess and 15 i f the di ameter i s greater than 2 i nches. You can
overri de the defaul t by speci fyi ng a val ue on the Rel i ef Devi ce Rupture Di sk
sheet.
I n the code capaci ty run, the rupture di sk i s model ed as an i deal nozzl e wi th a
certi fi ed di scharge coeffi ci ent. I f no certi fi ed di scharge coeffi ci ent i s avai l abl e, a
val ue of 0.62 i s suggested.
I n a code capaci ty run i n combi nati on wi th a safety rel i ef val ve, the resi stance of
the rupture di sk i s model ed by the combi nati on coeffi ci ent i n the val ve model .
Versi on 10
Chapter 10
The emergency rel i ef vent i s model ed as a nozzl e. A de-rati ng factor of 0.9 i s used
i n a code capaci ty run.
Piping System
The i nl et pi pi ng system can be made of one of the fol l owi ng:
One pi pe secti on
Two secti ons of pi pe pl us a vessel neck, al l wi th di fferent di ameters
The tai l pi pe can be made of one secti on of pi pe or of two secti ons of pi pe wi th
di fferent di ameters.
For each pi pe secti on, speci fy:
Pi pe di ameter
Length
El evati on
Whether the pi pes are screwed together or hel d together wi th fl anges or
wel ds
I f pi pes of di fferent di ameters are used, reducer and expander resi stance
coeffi ci ents ("K" factors) can be speci fi ed. ASPEN PLUS uses the equati on
K=4*fr*(L/D) to convert from resi stance coeffi ci ents to equi val ent L/D, where the
term "fr" i s the fri cti on factor. Opti onal i nformati on for each secti on consi sts of
the number of 90 degree el bows, strai ght tees, branched tees, gate val ves,
butterfl y val ves, transfl o val ves, and control val ves. You can add other fi tti ngs
not l i sted by speci fyi ng the L/D val ue. ASPEN PLUS cal cul ates a total equi val ent
L/D before model i ng the pi pe secti on.
You may al so speci fy:
Ambi ent temperature at the i nl et and outl et of the pi pe
A heat transfer coeffi ci ent to exchange heat wi th the pi pe contents
Whi l e model i ng the pi pe secti on, ASPEN PLUS detects the choked condi ti on i n
the pi pe by keepi ng track of the Mach Number as i ntegrati on down the pi pe
proceeds. I f the Mach Number goes above 1.0, i ntegrati on i s stopped and a fl ag i s
returned to i ndi cate that the pi pe choked.
Pi pel i ne pressure drop model i ng can work i n two ways. You may speci fy one of
the fol l owi ng:
Ri gorous fl ashes are to be done at each step i n the i ntegrati on
A fl ash tabl e i s used duri ng pi pe i ntegrati on
Versi on 10
Pressure
Relief
I f you request a tabl e, speci fy the number of temperature and pressure poi nts i n
the tabl e. At each temperature-pressure pai r, ASPEN PLUS performs a fl ash and
cal cul ates al l necessary properti es (densi ty, vi scosi ty, surface tensi on, and so on).
As i ntegrati on proceeds, ASPEN PLUS i nterpol ates i n thi s tabl e to get the
necessary properti es. I f properti es outsi de the tabl e are needed, a ri gorous fl ash
i s performed at that poi nt. I n general , the pi pe i ntegrati on proceeds faster i f the
fl ash tabl e i s used. Several correl ati ons are avai l abl e, dependi ng on the pi pe
i ncl i nati on. The defaul t method for al l i ncl i nati ons (hol dup and fri cti onal
pressure l oss) i s Beggs and Bri l l . Other avai l abl e opti ons are:
Darcy
Lockhart-Marti nel l i
Dukl er for fri cti onal l oss
Lockhart-Marti nel l i , Sl ack, and Fl ani gan for hol dup
Data Tables for Pipes and Relief Devices
Pres-Rel i ef i ncl udes several customi zabl e tabl es that l i st the avai l abl e opti ons for
pi pes, general purpose val ves, safety rel i ef val ves, emergency rel i ef vents, and
rupture di sks. You can modi fy the tabl es by changi ng data fi l es. Then process the
fi l es through Model Manager Tabl e Bui l di ng System (MMTBS).
Pipes
Pres-Rel i ef i ncl udes a tabl e of actual di ameters for several steel pi pe schedul es.
Use thi s tabl e when choosi ng the pi pi ng for the i nl et and tai l pi pes. You can modi fy
thi s tabl e by i ncl udi ng more pi pe materi al s and/or schedul es. The fol l owi ng secti on
shows the tabl e organi zati on.
Versi on 10
Chapter 10
fi rst materi al of constructi on
#of types
fi rst type
#of di ameters
nomi nal di ameter actual di ameter
.
.
second type
#of di ameters
.
.
second materi al of constructi on
#of types
fi rst type
#of di ameters
.
.
second type
.
.
General-Purpose Valves
For general -purpose val ves i n the i nl et or tai l pi pes, Pres-Rel i ef i ncl udes a tabl e of
vari ous manufacturers val ves from 1 i nch to 10 i nches. The val ves i ncl ude:
Durco Pl ug
Tufl i ne Pl ug
Jamesbury Bal l
AGCO Sel ector
KTM Bal l (L-Port and T-Port)
Versi on 10
Pressure
Relief
For each manufacturer, the tabl e contai ns:
Val ve type (for exampl e., L-Port or T-Port)
Nomi nal di ameter
Port area
Fl ow coeffi ci ent
The tabl e i s organi zed as fol l ows:
fi rst manufacturer
#of types
fi rst type
#of di ameters
nomi nal di ameter port area fl ow coeff
.
.
second type
#of di ameters
.
.
Safety Relief Valves
Pres-Rel i ef i ncl udes a tabl e of manufacturers safety rel i ef val ves. I t contai ns
val ves for l i qui d and gas/2-phase servi ce. For each val ve, the tabl e contai ns:
Servi ce
Type
Manufacturer
Seri es, si ze (for exampl e, 3L4)
Throat di ameter
I nl et di ameter
Outl et di ameter
Di scharge coeffi ci ent
Overpressure factor (for l i qui d servi ce val ves)
Versi on 10
Chapter 10
Servi ce (Li qui d, Gas, or 2-phase)
#of types
fi rst type
#of manufacturers
fi rst manufacturer
#of seri es
fi rst seri es
#of si zes
fi rst si ze
#of throat di ameters
throat di am i nl et di am outl et di am di schg coeff over pr factor
.
.
Emergency Relief Vents
Thi s tabl e contai ns:
Nomi nal di ameter
Effecti ve di ameter
Al l owed setpoi nt for several Protectoseal and Groth emergency rel i ef vents
You must speci fy an over-pressure factor. The tabl e i s organi zed as fol l ows:
fi rst manufacturer
#of types
fi rst type
#of nomi nal di ameters
nomi nal di ameter effecti ve di ameter al l owed setpoi nt
nomi nal di ameter effecti ve di ameter al l owed setpoi nt
.
.
Rupture Disks
Thi s tabl e contai ns manufacturers i nformati on on rupture di sks. Each entry
contai ns:
A manufacturer
Type
Nomi nal di ameter
Actual di ameter
Di scharge coeffi ci ent
Versi on 10
Pressure
Relief
fi rst manufacturer
#of types
fi rst type
#of nomi nal di ameters
fi rst nomi nal di am actual di am di scharge coeff
second nomi nal di am actual di am di scharge coeff
.
.
Valve Cycling
I f a rel i ef val ve i s too l arge for a gi ven appl i cati on, val ve cycl i ng may occur. I n thi s
si tuati on, the pressure i n the vessel bui l ds up to a poi nt where the val ve opens, but
then cl oses al most i mmedi atel y because enough materi al i s rel eased to l ower the
vessel pressure bel ow the cl osi ng pressure. I n some si mul ati ons, the val ve may
open and cl ose several ti mes per second. The si mul ati on may run for a l ong ti me,
just openi ng and cl osi ng the val ve over and over.
To stop such a si mul ati on, you can speci fy whether or not to stop cycl i ng, and
how many openi ngs and cl osi ngs of the val ve are al l owed i n a speci fi ed amount of
ti me.
Vessel Types
You must enter vessel geometry for the dynami c scenari os. You can choose one of
the fol l owi ng vessel types:
Verti cal Vessel
Hori zontal Vessel
API Tank
Sphere
Heat exchanger shel l
Vessel jacket
User-speci fi ed
I f you choose user-speci fi ed, you must speci fy surface area and vol ume. Surface
area i s al so requi red for vessel jacket. Maxi mum Al l owabl e Worki ng Pressure
(MAWP) wi th correspondi ng temperature i s requi red for al l vessel types. Some
vessel types requi re di ameter, l ength, and vol ume of i nternal s.
Versi on 10
Chapter 10
Vertical Vessel, Horizontal Vessel, and API Tank
I f you choose verti cal vessel , hori zontal vessel , or API tank, choose one of these
head types:
Fl anged and di shed
El l i psoi dal
User-speci fi ed
I f you choose user-speci fi ed head type, you must speci fy the area and vol ume of a
head.
Sphere
I f the protected vessel i s a sphere, you must speci fy:
Di ameter
MAWP wi th correspondi ng temperature
Vol ume of i nternal s
Heat Exchanger Shell
I f the protected vessel i s a heat exchanger shel l , i n addi ti on to the i tems speci fi ed
for a verti cal vessel you must al so speci fy whether the vessel i s mounted
verti cal l y or hori zontal l y.
Vessel J acket
I f the protected vessel i s a vessel jacket, you must speci fy:
Jacket vol ume
User-Specified
I f the protected vessel i s user-speci fi ed, you must speci fy:
Vol ume
Area
Versi on 10
Pressure
Relief
Disengagement Models
The fol l owi ng di sengagement opti ons are avai l abl e:
Option Description
Homogeneous Vapor fraction leaving vessel is the same as vapor fraction in vessel
All-vapor All vapor leaving vessel
All-liquid All liquid leaving vessel
Bubbly DIERS bubbly model
Churn-turbulent DIERS churn-turbulent model
User-specified Homogeneous venting until vessel vapor fraction reaches the user-specified value,
then all vapor venting
For the bubbl y and churn-turbul ent methods, ASPEN PLUS uses the DI ERS
swi tch-poi nt cal cul ati ons to compute the poi nt at whi ch total vapor-l i qui d
di sengagement occurs. Use the bubbl y and churn-turbul ent model s onl y for
verti cal or API tanks.
Stop Criteria
For dynami c scenari os, stop cri teri a need to be speci fi ed whi ch wi l l termi nate the
si mul ati on. You must:
Sel ect a speci fi cati on type
Enter a val ue for the speci fi cati on at whi ch the si mul ati on wi l l stop
Sel ect a component and substream for component-rel ated speci fi cati on types
Speci fy whi ch approach di recti on (above or bel ow) to use i n stoppi ng the
si mul ati on
You may sel ect from the fol l owi ng speci fi cati on types:
Si mul ati on ti me
Vapor fracti on i n the vessel
Mol e fracti on of a speci fi ed component
Mass fracti on of a speci fi ed component
Conversi on of a speci fi ed component
Total mol es or mol es of a speci fi ed component
Total mass or mass of a speci fi ed component
Vessel temperature
Vessel pressure
Vent mol e fl ow rate or mol e fl ow rate of a component
Vent mass fl ow rate or mass fl ow rate of a component
Versi on 10
Chapter 10
You must al so sel ect the l ocati on of the stop cri teri a speci fi cati on. You may sel ect
from the fol l owi ng l ocati ons:
Vessel
Rel i ef vent system
Accumul ator
Certai n restri cti ons appl y dependi ng on the l ocati on sel ected.
When l ocati on = vessel , mol e and mass fl ow rate are not al l owed.
When l ocati on = vent accumul ator, onl y the fol l owi ng speci fi cati ons are al l owed:
Total mol es of a speci fi ed component
Total mass of a speci fi ed component
When l ocati on = vent, onl y the fl owi ng speci fi cati ons are al l owed:
Vent mol ar fl ow rate
Vent mass fl ow rate
Solution Procedure for Dynamic Scenarios
The probl em to be sol ved i s:
Gi ven the i ni ti al condi ti ons i n the vessel , a descri pti on of the pressure rel i ef
system, and the heat fl ow i nto the vessel , cal cul ate the fl ow rate through the
pressure rel i ef system and determi ne i f the pressure rel i ef system meets code
requi rements.
The probl em i s sol ved as outl i ned bel ow. Thi s al gori thm i s for the Heat-I nput and
Fi re Scenari os.
1. Gi ven the heat i nput to the vessel , sol ve the energy bal ance and fl ash
equati ons al ong wi th the reacti on equati ons for the vessel at the present ti me
step. I f any of the termi nati on cri teri a are met, go to Step 6. The opti ons for
speci fyi ng termi nati on cri teri a i ncl ude:
Ti me for scenari o exceeded
Speci fi ed vapor fracti on reached
Vessel contents have reached speci fi ed val ue
Pressure i n the vessel i s greater than the maxi mum al l owed
2. I f the pressure i n the vessel i s l ess than the devi ce openi ng pressure,
i ncrement ti me and go to Step 1.
Versi on 10
Pressure
Relief
3. Cal cul ate the maxi mum fl ow rate possi bl e through the pressure rel i ef system.
Thi s val ue i s cal cul ated by fi ndi ng the smal l est di ameter of any pi pe or val ve
i n the system, and cal cul ati ng the soni c vel oci ty through that di ameter.
4. Cal cul ate the pressure at the end of the vessel neck, after each secti on of the
i nl et pi pe, after the pressure rel i ef devi ce, and after each secti on of the tai l
pi pe based on the current fl ow esti mate. I f the pressure at the end of any
secti on i s l ess than the user -speci fi ed di scharge pressure, i t i s not necessary
to do the cal cul ati ons for the next secti on.
5. I f the pressure at the end of the pressure rel i ef system i s wi thi n tol erance of
the user -speci fi ed di scharge pressure, i ncrement ti me and go to Step 1.
Otherwi se, cal cul ate a new guess for the fl ow through the rel i ef system and
go to Step 4.
6. Gi ven the fl ow at any ti me, check where the choke poi nt i s. I f the choke poi nt
i s not at the pressure rel i ef val ve, the system i s unacceptabl e. Check i f any
appl i cabl e codes are vi ol ated. I f so, the system i s unacceptabl e.
Flow Equations
Pipe Flow
Thi s i s the general di fferenti al equati on for fl ow through a constant di ameter pi pe:

dp G d f
D
dL g dL + +
_
,
1
]
1
+
2
2
4
2
0 sin (1)
Where:
= Speci fi c vol ume of stream
p = Stati c (fl owi ng) pressure of stream
G = Mass fl ow rate per uni t area
f = Fri cti on factor
D = I nsi de di ameter of pi pe
L = Equi val ent pi pe l ength
g = Accel erati on due to gravi ty
si n = Verti cal ri se/equi val ent pi pe l ength
Versi on 10
Chapter 10
represents the physi cal angl e of the pi pe wi th respect to the hori zontal onl y i f
the equi val ent pi pe l ength i s the same as the physi cal fl ow path l ength (that i s,
onl y pi pe, no fi tti ngs or other resi stances). The potenti al energy term i n the
equati on assumes that the verti cal el evati on i s di stri buted evenl y al ong the
enti re equi val ent l ength.
For exampl e, you have onl y a si ngl e 20 meter l ength of pi pe that ri ses a total of
si x meters, then
sin .
6
20
0 3
I f the same system al so i ncl udes a fi tti ng resi stance of 5 equi val ent meters, then:
sin .
+
6
20 5
0 24
Equati on (1) appl i es to any fl ow system (al l vapor, non-fl ashi ng l i qui d, fl ashi ng
two-phase, non-fl ashi ng two-phase, etc.). Al l that i s needed to sol ve the equati on
i s the proper rel ati onshi p between the pressure (p) and the stream speci fi c
vol ume ( ). Thi s rel ati onshi p i s determi ned by the type of constrai nt chosen.
For adi abati c fl ow, the defi ni ng equati on i s:
H KE PE CONSTANT + +
Where:
H = Stream enthal py
KE = Ki neti c energy of stream
PE = Potenti al energy of stream
Between poi nts 1 and 2:
H KE PE H KE PE
1 1 1 2 2 2
+ + + +
Thus:
H H KE PE
2 1

ASPEN PLUS fl ash routi nes can be used to cal cul ate enthal py at poi nt 2.
Versi on 10
Pressure
Relief
Nozzle Flow
ASPEN PLUS cal cul ates nozzl e fl ow by treati ng the fl ow as adi abati c through a
perfect nozzl e whi ch has no fri cti on l osses and i s short enough so that any potenti al
energy effects can be negl ected. The actual fl ow i s then cal cul ated by appl yi ng a
correcti on factor (the fl ow coeffi ci ent, Cd) to the fl ow cal cul ated as i f the nozzl e
behaved as perfect. Fri cti onl ess fl ow i s descri bed by:
udu dp + 0 (2)
Where:
u = Stream l i near vel oci ty
= Speci fi c vol ume of stream
For adi abati c fl ow:
d U PV
u
PE + + +
_
,

2
2
0
Where:
U = I nternal energy
PV = Pressure-vol ume product
Negl ecti ng PE, and combi ni ng the defi ni ti on of enthal py (H =U +PV) i nto thi s
equati on gi ves:
dH udu + 0 (3)
Combi ni ng (2) and (3) gi ves:
dH dp (4)
By defi ni ti on:
dH dp (5)
(4) and (5) yi el d:
Tds 0
or
ds 0
Thus, adi abati c fri cti onl ess fl ow i s i sentropi c.
Versi on 10
Chapter 10
The fl ow equati on (2) can be i ntegrated to descri be the fl ow through a perfect
nozzl e as fol l ows:
Let p
0
= The upstream stagnati on pressure where the vel oci ty i s zero (u
0
= 0).
Let p
1
= The pressure i n the nozzl e throat at whi ch the fl ow i s accel erated to
vel oci ty u.
Thus, the i ntegrated form of (2) becomes:
1
2
2
01
1
u dp
p
p

whi ch can be re-wri tten (noti ng that u = G ):

G dp
p
p
2
1
2
2
0
1

(6)
Equati on (6) provi des the means to cal cul ate the fl ow rate through a perfect
nozzl e gi ven the upstream stagnati on pressure and the proper p-v rel ati onshi p
(whi ch i s i sentropi c). As one i ntegrates (6) from p
0
to p
1
, a maxi mum G i ndi cates
that the fl ow has become choked at the current val ue of p. (6) al so serves as a
method for converti ng between stagnati on and stati c pressures at any poi nt i n
the fl ow system (pi pe or nozzl e).
Calculation and Convergence Methods
ASPEN PLUS uses the same equati ons used to model the safety rel i ef val ve as to
model the conversi on from stagnati on to fl owi ng pressure and back agai n. To be
compl etel y accurate, the val ve shoul d be model ed as i n equati on (6) i n the Nozzl e
Fl ow secti on, this chapter. Thi s model requi res that constant entropy fl ashes be
performed at each poi nt i n the i ntegrati on of equati on (6). Thi s i s a very ti me
consumi ng cal cul ati on, so several opti ons are provi ded to speed up the cal cul ati ons.
Fi rst, you can choose to do constant enthal py fl ashes rather than constant entropy
fl ashes through the nozzl e. Thi s speeds up the cal cul ati ons by an order of
magni tude, si nce the constant entropy fl ash i s model ed by a seri es of constant
enthal py fl ashes convergi ng on entropy.
ASPEN PLUS al so provi des a shortcut method to cal cul ate mol ar vol ume as a
functi on of pressure duri ng the nozzl e i ntegrati on. Thi s method was devel oped by
L. L. Si mpson
1
and gi ves very good resul ts. I nstead of doi ng a fl ash cal cul ati on to
cal cul ate the mol ar vol ume at each poi nt i n the i ntegrati on, two fl ashes are done
at the start and parameters are cal cul ated whi ch al l ow you to cal cul ate the mol ar
vol ume at other pressures wi thout doi ng fl ashes.
Versi on 10
Pressure
Relief
Vessel Insulation Credit Factor
When Fi re Standard API -520 or API -2000 i s used, you may cl ai m an i nsul ati on
credi t factor cal cul ated from the formul a:
( )
F
k Tf
t
1660
21000
Where:
k = Thermal conducti vi ty of i nsul ati on, i n Bri ti sh thermal uni ts per
hour per square foot per degree Fahrenhei t per i nch at mean
temperature.
Tf = Temperature of vessel contents at rel i evi ng condi ti ons, i n degrees
Fahrenhei t.
t = Thi ckness of i nsul ati on, i n i nches.
Assumi ng a k val ue of 4.0, and Tf of 0.0, the fol l owi ng tabl e, whi ch was taken
from API -2000, gi ves val ues of F for vari ous val ues of i nsul ati on thi ckness:
Insulation thickness (t) F Factor
6 inches (152 millimeters) 0.05
12 inches (305 millimeters)
or more
0.025
Versi on 10
Chapter 10
References
Si mpson, L.L., "Esti mate Two-Phase Fl ow i n Safety Devi ces," Chemical
Engineering, August, 1991, pp. 98-102.
Additional Reading
"Si zi ng, Sel ecti on, and I nstal l ati on of Pressure-Rel i evi ng Devi ces i n Refi neri es"
Part I - Si zi ng and Sel ecti on, API Recommended Practi ce 520, Ameri can
Petrol eum I nsti tute, 1220 L Street Northwest, Washi ngton, D.C. 20005.
"Venti ng Atmospheri c and Low Pressure Storage Tanks," (Non-refri gerated and
Refri gerated), API Standard 2000, Ameri can Petrol eum I nsti tute, 1220 L Street
Northwest, Washi ngton, D.C. 20005.
O O O O
Versi on 10
Pressure
Relief
Uni t Operati on Model s A-1
Versi on 10
Appendix A
A Sizing and Rating for
Trays and Packings
ASPEN PLUS has extensi ve capabi l i ti es to si ze, rate, and perform pressure drop
cal cul ati ons for trayed and packed col umns. Use the fol l owi ng Tray/Packi ng forms
to enter speci fi cati ons:
TraySi zi ng
TrayRati ng
PackSi zi ng
PackRati ng
These capabi l i ti es are avai l abl e i n the fol l owi ng col umn uni t operati on model s:
RadFrac
Mul ti Frac
PetroFrac
You can choose from the fol l owi ng fi ve commonl y-used tray types:
Bubbl e caps
Si eve
Gl i tsch Bal l ast
Koch Fl exi tray
Nutter Fl oat Val ve

ASPEN PLUS can model a vari ety of random packi ngs. You can al so use any of
the fol l owi ng types of structured packi ngs:
Goodl oe
Gl i tsch Gri d
Norton I ntal ox Structured Packi ng

Sul zer BX, CY, Mel l apak, and Kerapak
Koch Fl exi pac, Fl exerami c, Fl exi gri d
A-2 Uni t Operati on Model s
Versi on 10
Sizing and
Rating for
Trays and
Packings
For si zi ng and rati ng cal cul ati ons, ASPEN PLUS di vi des a col umn i nto secti ons.
Each secti on can have a di fferent tray type, packi ng type, and di ameter. The tray
detai l s can vary from secti on to secti on. A col umn can have an unl i mi ted number
of secti ons. I n addi ti on, you can si ze and rate the same secti on wi th di fferent
types of trays and packi ngs.
The cal cul ati ons are based on vendor-recommended procedures whenever these
are avai l abl e. When vendor procedures are not avai l abl e, wel l -establ i shed
l i terature methods are used.
ASPEN PLUS cal cul ates si zi ng and performance parameters such as:
Col umn di ameter
Fl oodi ng approach or approach to maxi mum capaci ty
Downcomer backup
Pressure drop
These parameters are based on:
Col umn l oadi ngs
Transport properti es
Tray geometry
Packi ng characteri sti cs
You can use the computed pressure drop to update the col umn pressure profi l e.
Single-Pass and Multi-Pass Trays
You can use the col umn model s i n ASPEN PLUS to:
Si ze one- and two-pass trays
Rate trays wi th up to four passes
Schemati cs of one-, two-, three-, and four-pass trays are shown i n the next four
fi gures. ASPEN PLUS performs and reports rati ng cal cul ati ons for al l panel s.
When speci fyi ng Wei r hei ghts, cap posi ti oni ng, and number of val ves:
For Specify
One-pass tray A single value
Two-pass tray Up to two values, one for each panels A and B
Three-pass tray Up to three values, one for each panel (A, B and C)
Four-pass tray Up to four values, one for each panel (A, B, C and D)
Versi on 10
Appendix A
The val ues for the number of caps and number of val ves appl i es for each panel .
For exampl e, two-pass trays have two A panel s for tray AA, and two B panel s for
tray BB. Therefore, the number of caps per panel i s the number of caps per tray
di vi ded by two. Si mi l ar consi derati on i s necessary for three- and four-pass trays.
I f you speci fy onl y one val ue for mul ti -pass trays, that val ue appl i es to al l panel s.
When speci fyi ng downcomer cl earance and wi dth:
For Specify
One-pass tray A single value for the side downcomer
Two-pass tray Up to two values, one for the side downcomer, one for the center downcomer
Three-pass tray Up to two values, one for the side downcomer, one for the off-center downcomer
Four-pass tray Up to three values: one for the side downcomer, one for the center downcomer, and one for
the off-center downcomer
Versi on 10
Sizing and
Rating for
Trays and
Packings
DC-WTOP
WEIR-HT
DC-HT
DC-
WBOT
O
u
t
l
e
t

W
e
i
r

L
e
n
g
t
h
Column Diameter
DC-CLEAR
A One-Pass Tray
Versi on 10
Appendix A
DC-
WTOP
DC-CLEAR
DC-CLEAR
Panel A
Panel B
WEIR-HT
DC-HT
DC-HT
DC-
WBOT
DC-
WBOT
Tray AA
Side
Downcomer
Tray BB
Center
Downcomer
Below
CTR. DC
CTR. DC
~
~
~
~
~
~
DC-WTOP
Column Diameter
O
u
t
l
e
t

W
e
i
r

L
e
n
g
t
h
A Two-Pass Tray
Versi on 10
Sizing and
Rating for
Trays and
Packings
DC-WTOP
DC-WBOT
DCOF
Panel A. B. C.
Panel A. B. C.
Panel C. B. A.
B A C
DC-WTOP DC-WTOP
B A
OFF-CTR.DC
OFF-CTR.DC
WEIR-HT
DC-HT
DC-
CLEAR
Column Diameter
O
u
t
l
e
t

W
e
i
r

L
e
n
g
t
h
A Three-Pass Tray
Versi on 10
Appendix A
OFF-CTR.DC OFF-CTR.DC
SIDE DC
CTR.DC
DC-WTOP DC-WTOP
WEIR-HT
DC-HT
DC-WBOT DC-WBOT
Panel A. B.
Panel C. D.
Panel A. B.
DCOF
DC-
CLEAR
D D
C
A A B B
Column Diameter
O
u
t
l
e
t

W
e
i
r

L
e
n
g
t
h
A Four-Pass Tray
Versi on 10
Sizing and
Rating for
Trays and
Packings
Modes of Operation for Trays
ASPEN PLUS provi des two modes of operati on for trays:
Si zi ng
Rati ng
I n ei ther mode, you can di vi de a col umn i nto any number of secti ons. Each
secti on can have a di fferent col umn di ameter, tray type, and tray geometry. You
can re-rate or re-desi gn the same secti on wi th di fferent tray types and/or
packi ngs.
ASPEN PLUS performs the cal cul ati ons one secti on at a ti me. I n si zi ng mode,
the col umn model determi nes tray di ameter to sati sfy the fl oodi ng approach you
speci fi ed for each stage. The l argest di ameter i s sel ected.
I n rati ng mode, you speci fy the col umn secti on di ameter and other tray detai l s.
For each stage, the col umn model cal cul ates tray performance and hydraul i c
i nformati on such as fl oodi ng approach, downcomer backup, and pressure drop.
Flooding Calculations for Trays
For bubbl e caps and si eve trays, ASPEN PLUS provi des two procedures for
cal cul ati ng the approach to fl oodi ng. The fi rst procedure i s based on the Fai r
1
method. The second uses the Gl i tsch procedure
2
for bal l ast trays. Thi s procedure
de-rates the cal cul ated fl oodi ng approach by 15% for bubbl e caps and by 5% for
si eve trays. Al l other hydraul i c cal cul ati ons are based on the Fai r and Bol l es
1,3
methods. For si zi ng cal cul ati ons, you can al so suppl y your own cal cul ati on
procedure:
= Specify On form
Flooding calculation method = USER TraySizing or PackSizing
Subroutine name UserSubroutines
For val ve trays (Gl i tsch Bal l ast, Koch Fl exi tray, and Nutter Fl oat Val ve trays),
ASPEN PLUS uses procedures from vendor desi gn bul l eti ns.
2,4,5
Versi on 10
Appendix A
Bubble Cap Tray Layout
RadFrac uses cap di ameter onl y for tray type CAPS. Val i d entri es are:
Cap Diameter Default Weir Height
Inches Millimeters Inches Millimeters
3 76.2 2.75 69.85
4 101.6 3.00 76.20
6 152.4 3.25 82.55
Use the cap di ameter to retri eve cap characteri sti cs based on standard cap
desi gns.
For columns with diameter The default is
Up to 48 in (1219.2 mm). 3 in (76.2 mm)
Greater than 48 in (1219.2
mm)
4 in (101.6 mm)
The fol l owi ng tabl e l i sts standard cap desi gns:
Materials Stainless Steel
Nominal Size, in 3 4 6
Cap
U.S. Standard gauge 16 16 16
OD, in 2.999 3.999 5.999
ID, in 2.875 3.875 5.875
Height overall, in 2.500 3.000 3.750
Number of slots 20 26 39
Type of slots Trapezoidal Trapezoidal Trapezoidal
Slot width, in
Bottom 0.333 0.333 0.333
Top 0.167 0.167 0.167
Slot height, in 1.000 1.250 1.500
Height shroud ring, in 0.250 0.250 0.250
continued
Versi on 10
Sizing and
Rating for
Trays and
Packings
Materials Stainless Steel
Nominal size, in 3 4 6
Riser
U.S. Standard gauge 16 16 16
OD, in 1.999 2.624 3.999
ID, in 1.875 2.500 3.875
Standard heights, in
0.5-in skirt height 2.250 2.500 2.750
1.0-in skirt height 2.750 3.000 3.250
1.5-in skirt height 3.250 3.500 3.750
Riser-slot seal, in 0.500 0.500 0.500
Cap areas, in
Riser 2.65 4.80 11.68
Reversal 4.18 7.55 17.80
Annular 3.35 6.38 14.55
Slot 5.00 8.12 14.64
Cap 7.07 12.60 28.30
Area ratios
Reversal/riser 1.58 1.57 1.52
Annular/riser 1.26 1.33 1.25
Slot/riser 1.89 1.69 1.25
Slot/cap 0.71 0.65 0.52
Pressure Drop Calculations for Trays
Normal l y, RadFrac, Mul ti Frac, and PetroFrac treat the stages you enter as
equi l i bri um stages. You must enter overal l effi ci ency to:
Convert the cal cul ated pressure drop per tray to pressure drop per
equi l i bri um stage
Compute the col umn pressure drop
I f you do not enter overal l effi ci ency, these model s assume 100% effi ci ency. I f you
speci fy Murphree or vapori zati on effi ci ency, you shoul d not enter overal l
effi ci ency. RadFrac, Mul ti Frac, and PetroFrac wi l l treat the stages as actual
trays.
Versi on 10
Appendix A
Foaming Calculations for Trays
Suggested val ues for Bal l ast trays are:
Service System Foaming Factor
Non-foaming systems 1.00
Fluorine systems 0.90
Moderate foamers, such as oil
absorbers, amine, and glycol
regenerators
0.85
Heavy foamers, such as
amine and glycol absorbers
0.73
Severe foamers, such as MEK
units
0.60
Foam stable systems, such as
caustic regenerators
0.30
Suggested val ues for Fl exi trays are:
Depropanizers 0.85-0.95
Absorbers 0.85
Vacuum towers 0.85
Amine regenerators 0.85
Amine contactors 0.70-0.80
High pressure deethanizers 0.75-0.80
Glycol contactors 0.70-0.75
Suggested val ues for Fl oat val ve trays are:
Non foaming 1.00
Low foaming 0.90
Moderate foaming 0.75
High foaming 0.60
Versi on 10
Sizing and
Rating for
Trays and
Packings
Packed Columns
The cal cul ati ons for packi ngs are based on the hei ght equi val ent of a theoreti cal
pl ate (HETP). HETP=packed hei ght/number of stages. The HETP i s requi red.
You can provi de i t usi ng one of the fol l owi ng methods:
Enter i t di rectl y on the PackSi zi ng or PackRati ng forms
Enter the packi ng hei ght on the same form
Packing Types and Packing Factors
ASPEN PLUS can handl e a wi de vari ety of packi ng types, i ncl udi ng di fferent
si zes and materi al s from vari ous vendors.
For random packi ngs, the cal cul ati ons requi re packi ng factors. ASPEN PLUS
stores packi ng factors for the vari ous si zes, materi al s, and vendors al l owed i n a
databank. I f you provi de the fol l owi ng i nformati on, ASPEN PLUS retri eves these
packi ng factors automati cal l y for cal cul ati ons:
Packi ng type
Si ze
Materi al
You may speci fy the vendor on the PackSi zi ng or PackRati ng form.
Is the vendor
specified? ASPEN PLUS uses
Yes The packing factor published by the vendor
No A value compiled from various literature sources
,
Fair, J .R., et al., "Liquid-Gas Systems," Perrys Chemical Engineers Handbook, R.H. Perry and D.
Green, ed., 6th ed. (New York: McGraw Hill, 1984).
Tower Packings, Bulletin No. 15 (Tokyo: Tokyo Special Wire Netting Company).
You can enter the packi ng factor di rectl y to overri de the bui l t-i n val ues. ASPEN
PLUS uses the packi ng type to sel ect the proper cal cul ati on procedure.
Modes of Operation for Packing
The col umn model s have two modes of operati on for packi ng:
Si zi ng
Rati ng
Versi on 10
Appendix A
I n ei ther mode, you can di vi de a col umn i nto any number of secti ons. Each
secti on can have di fferent packi ngs. You can re-rate or re-desi gn the same secti on
wi th di fferent packi ngs and/or tray types. ASPEN PLUS performs the
cal cul ati ons one secti on at a ti me.
I n si zi ng mode, ASPEN PLUS determi nes the col umn secti on di ameter from:
The approach to the maxi mum capaci ty
A desi gn capaci ty factor you speci fy
You can i mpose a maxi mum pressure drop per uni t hei ght (of packi ng or per
secti on) as an addi ti onal constrai nt. Once ASPEN PLUS has determi ned the
col umn secti on di ameter, i t re-rates the stages i n the secti on wi th the cal cul ated
di ameter.
I n rati ng mode, you speci fy the col umn di ameter. ASPEN PLUS cal cul ates the
approach to maxi mum capaci ty and pressure drop.
Maximum Capacity Calculations for Packing
ASPEN PLUS provi des several methods for maxi mum capaci ty cal cul ati ons. For
random packi ngs you can use:
Method For this type of packings
Mass Transfer, Ltd. (MTL)
MTL
Norton
Norton IMTP
Koch
Koch
Eckert All other random packings
Cascade Mini-Ring Design Manual (Tokyo: Dodwell & Company, Ltd., 1984).
I ntalox High-Performance Separation Systems, Bulletin I HP-1 (Akron: Norton Company, 1987).
McNulty, K.J ., "Hydraulic Model for Packed Tower Design." Paper presented at the American I nstitute
of Chemical Engineers Spring Meeting in Houston, 1993.
For structured packi ngs, ASPEN PLUS provi des vendor procedures for each type.
I f you speci fy the maxi mum capaci ty factor, ASPEN PLUS bypasses the
maxi mum capaci ty cal cul ati ons.
The defi ni ti on of approach to maxi mum capaci ty depends on the type of packi ngs.
Versi on 10
Sizing and
Rating for
Trays and
Packings
For Norton I MTP and I ntal ox structured packi ngs, approach to maxi mum
capaci ty refers to the fracti onal approach to the maxi mum effi ci ent capaci ty.
Effi ci ent capaci ty i s the operati ng poi nt at whi ch effi ci ency of the packi ng
deteri orates due to l i qui d entrai nment. The effi ci ent capaci ty i s approxi matel y 10
to 20% bel ow the fl ood poi nt.
For Sul zer structured packi ngs (BX, CY, Kerapak, and Mel l apak), approach to
maxi mum capaci ty refers to the fracti onal approach to maxi mum capaci ty.
Maxi mum capaci ty i s the operati ng poi nt at whi ch a pressure drop of 12 mbar/m
(1.47 i n-water/ft) of packi ng i s obtai ned. At thi s condi ti on, stabl e operati on i s
possi bl e, but the gas l oad i s hi gher than that at whi ch maxi mum separati on
effi ci ency i s achi eved.
The gas l oad correspondi ng to the maxi mum capaci ty i s 5 to 10% bel ow the fl ood
poi nt. Sul zer recommends a usual desi gn range between 0.5 and 0.8 for approach
to fl oodi ng.
For al l other packi ngs, approach to maxi mum capaci ty refers to the fracti onal
approach to the fl ood poi nt.
Because there are di fferent defi ni ti ons for approach to maxi mum capaci ty, si zi ng
resul ts are not on the same basi s for packi ngs from di fferent vendors, even when
you use the same val ue for approach to maxi mum capaci ty. Di rect performance
compari son of packi ngs from di fferent vendors i s not recommended.
The capaci ty factor i s:
CS VS
V
L V

Where:
CS = Capaci ty factor
VS = Superfi ci al vel oci ty of vapor to packi ng
V = Densi ty of vapor to packi ng
L = Densi ty of l i qui d from packi ng

Versi on 10
Appendix A
Pressure Drop Calculations for Packing
For random packi ngs, ASPEN PLUS provi des several bui l t-i n methods to
compute the pressure drop.
Vendor Pressure drop method
MTL Vendor
Norton Vendor procedure

, ,
Koch Vendor procedure
Not specified Eckert GPDC
, Norton GPDC
, ,
,

Prahl GPDC
, Tsai GPDC
Cascade Mini-Ring Design Manual (Tokyo: Dodwell & Company, Ltd., 1984).
Dolan, M.J . and Strigle, R.F., "Advances in Distillation Column Design," CEP, Vol.76, No.11
(November 1980), pp. 78-83.
I ntalox High-Performance Separation Systems, Bulletin I HP-1 (Akron: Norton Company, 1987).
I ntalox Metal Tower Packing, Bulletin I M82 (Akron: Norton Company, 1979).
Fair, J .R., et al., "Liquid-Gas Systems," Perrys Chemical Engineers Handbook, R.H. Perry and D.
Green, ed., 6th ed. (New York: McGraw Hill, 1984), pp. 18-22.
McNulty, K.J . and Hsieh, C.L., "Hydraulic Performance and Efficiency of Koch Flexipac Structured
Packings." Paper presented at American I nstitute of Chemical Engineers Annual Meeting in Los
Angeles, 1982.
Tsai, T.C. "Packed Tower Program Has Special Features," Oil and Gas J ournal, Vol. 83 No. 35
(September, 1985), p. 77.
I f you speci fy the vendor, ASPEN PLUS uses the vendor procedure. I f you do not
speci fy the vendor, you can choose one of four di fferent pressure drop methods. I f
you do not speci fy a method, ASPEN PLUS uses the Eckert general i zed pressure
drop correl ati on (GPDC).
Versi on 10
Sizing and
Rating for
Trays and
Packings
For structured packi ngs, vendor pressure drop correl ati ons are avai l abl e for al l
packi ngs:
Packing type Pressure drop method
Goodloe Vendor procedure
Glitsch Grid Vendor procedure
Norton Intalox Structured Packings Vendor procedure
Sulzer BX, CY, Mellapak, and Kerapak Vendor procedure
Koch Flexipac, Flexeramic, and Flexigrid Vendor procedure
Goodloe, Bulletin 520A (Dallas: Glitsch, I nc., 1981).
Glitsch Grid-Grid/ Ring Combination Bed, Bulletin No. 7070 (Dallas: Glitsch, I nc., 1978).
Norton Company, private communication, 1992.
Spiegel, L. and Meier, W., "Correlations of the Performance Characteristics of the Various Mellapak
Types." Paper presented at the 4th I nternational Symposium of Distillation and Absorption, Brighton,
England, 1987.
Liquid Holdup Calculations for Packing
ASPEN PLUS performs l i qui d hol dup cal cul ati ons for both random and
structured packi ngs. The cal cul ati ons use the Sti chl mai r
6
correl ati on. The
Sti chl mai r correl ati on requi res these parameters:
Packi ng voi d fracti on and surface area
Three Sti chl mai r correl ati on constants
ASPEN PLUS provi des these parameters for a vari ety of packi ngs i n the bui l t-i n
packi ng databank. I f these parameters are mi ssi ng for a parti cul ar packi ng,
ASPEN PLUS wi l l not perform l i qui d hol dup cal cul ati ons for that packi ng.
You can al so enter these parameters to provi de mi ssi ng val ues, or to overri de the
databank val ues.
Versi on 10
Appendix A
Pressure Profile Update
You can update the pressure profi l e usi ng:
Computed pressure drops for the rati ng mode of both trays and packi ngs
The si zi ng mode of packi ngs
I f you choose to update the pressure profi l e, the col umn model s sol ve the tray or
packi ng cal cul ati on procedures si mul taneousl y wi th the col umn-descri bi ng
equati ons. For updati ng the pressure profi l e duri ng cal cul ati ons check Update
Secti on Pressure Profi l e on the fol l owi ng forms:
TrayRati ng
PackSi zi ng
PackRati ng
Al so, you can fi x the pressure at the top or bottom of the col umn and you can
speci fy thi s opti on on the above forms. The stage pressures become addi ti onal
vari abl es. ASPEN PLUS uses the pressure speci fi cati ons gi ven on the
Pres-Profi l e form to:
I ni ti al i ze the col umn pressure profi l e
Fi x the pressure drop of stages for whi ch the pressure profi l e i s not updated
Physical Property Data Requirements
Several physi cal properti es that are not normal l y used for heat and materi al
bal ance cal cul ati ons are requi red for col umn si zi ng and rati ng. These properti es
are:
Li qui d and vapor densi ti es
Li qui d surface tensi on
Li qui d and vapor vi scosi ti es
The physi cal property method that you speci fy for a uni t operati on model must be
abl e to provi de the requi red properti es. I n addi ti on, the physi cal property
parameters needed to cal cul ate the requi red properti es must be avai l abl e for al l
components i n the col umn. See the descri pti ons of properti es i n the ASPEN
PLUS User Guide Vol ume 1, for detai l s on speci fyi ng physi cal property methods
and determi ni ng property parameter requi rements.
Versi on 10
Sizing and
Rating for
Trays and
Packings
References
1. Fai r, J.R., et al ., Li qui d-Gas Systems, Perrys Chemical Engineers'
Handbook, R.H. Perry and D. Green, ed. 6
th
ed., New York: McGraw Hi l l ,
1984.
2. Ballast Tray Design Manual , Gl i tsch, I nc., Bul l eti n No. 4900, 3
rd
ed.,
Dal l as:1980.
3. Smi th, B.D., Tray Hydraul i cs: Bubbl e Cap Trays and Tray Hydraul i cs:
Perforated Trays, Design of Equilibrium Stage Processes, New York:
McGraw Hi l l , 1963, pp. 474-569.
4. Koch Flexitray Design Manual, Koch Engi neeri ng Co., I nc. Bul l eti n No. 90,
Wi chi ta.
5. Nutter Float Valve Design Manual , Tul sa: Nutter Engi neeri ng Co., 1976.
6. Sti chl mai r, J., et al ., "General Model for Predi cti on of Pressure Drop and
Capaci ty of Countercurrent Gas/Li qui d Packed Col umns," Gas Separation
and Purification, Vol . 3 (1989), p. 22.
O O O O
Uni t Operati on Model s I ndex-1
Versi on 10
I ndex
A
Absorbers
MultiFrac 4-30
RadFrac 4-23
RateFrac 4-62
Aerotran
flash specifications 3-27
flowsheet connectivity 3-26
overview 3-26
physical properties 3-28
solids 3-28
specifying 3-27
AGA method
Pipe model 6-39
Pipeline 6-51
Air separation
MultiFrac 4-30
Air-cooled heat exchangers
Aerotran 3-26
Algorithms
convergence 4-22, 4-25, 4-27, 4-28, 4-42, 4-58
inside-out 4-26, 4-43
Newton 4-22, 4-26, 4-42, 4-44
nonideal 4-22, 4-26
standard 4-26, 4-42, 4-43
sum-rates 4-22, 4-26, 4-42, 4-43
Angel-Welchon-Ros correlation
Pipe model 6-38
Pipeline 6-49
ASME method
Compr 6-10
MCompr 6-15
Azeotropic distillation
RadFrac 4-22
B
Baffle geometry
HeatX 3-13
Baghouses
FabFl 8-23
resistance coefficients 8-25
separation efficiency 8-26
Ballast trays
values A-11
Batch reactors
RBatch 5-25
Beggs and Brill correlation
Pipe model 6-37
Pipeline 6-48
Beggs and Brill correlation parameters
Pipe model 6-38
Pipeline 6-50
B-JAC
Aerotran interface 3-26
Hetran interface 3-23
Bolles method
tray flooding calculations A-8
Bond work index (BWI)
Crusher 8-14, 8-17
Brake horsepower
Compr 6-12
MCompr 6-17
Bubble cap trays
cap diameter A-9
C
Cavitation index
Valve model 6-29
CCD
component attributes 8-66
medium temperature 8-67
mixing efficiency 8-66
overview 8-64
profiles 8-66
pseudostreams 8-65
specifying 8-65
Centrifuge filters
CFuge 8-52
CFuge
filter cake 8-53
filtrate flow rate 8-54
overview 8-52
I ndex-2 Uni t Operati on Model s
Versi on 10
CFuge (continued)
pressure drop 8-54
rating 8-53
sizing 8-53
specifying 8-53
Chilton-Colburn analogy
RateFrac 4-77, 4-84
ClChng
overview 7-6
specifying 7-6
stream class change 7-6
Coal
grinding 8-18
Column configuration
RateFrac 4-70
Columns
Distl 4-6
DSTWU 4-3
Extract 4-87
MultiFrac 4-30
packings A-12
PetroFrac 4-48
physical property requirements A-17
pressure drop calculations A-1
RadFrac 4-11, 4-16
RateFrac 4-62
rating A-1
SCFrac 4-8
sizing A-1
Component ratio
RateFrac 4-75
Component separators
Sep 2-12
Sep2 2-14
Compr
ASME method 6-10
GPSA method 6-10
isentropic efficiency 6-12
mechanical efficiency 6-12
Mollier method 6-10
net work load 6-10
overview 6-9
performance curves 6-10
polytropic efficiency 6-11
specifying 6-10
steam pressure 6-9
Compressors
Compr 6-9
Heater model 3-2
Compressors (continued)
MCompr 6-13
Condensers
PetroFrac 4-51
RateFrac 4-71
Connecting streams
RateFrac 4-70
Continuous stirred tank reactor
RCSTR 5-16
Convergence
algorithms 4-42, 4-43
RateFrac 4-76
Convergence algorithms
PetroFrac 4-58
RadFrac 4-25
Coolers
Heater model 3-2
RadFrac 4-17
RateFrac 4-73
Crude units
SCFrac 4-8
Crusher
Bond work index (BWI) 8-14, 8-17
breakage functions 8-14
Hardgrove grindability index (HGI) 8-14, 8-18
overview 8-13
power requirement 8-16
primary crusher 8-16
reduction ratios 8-16
secondary crusher 8-16
selection functions 8-14
specifying 8-14
Cryogenic applications
RadFrac 4-23
Crystallizer
crystal growth rate 8-7
crystal nucleation rate 8-8
magma recirculation 8-5
overview 8-3
particle size distribution (PSD) 8-9, 8-10
population balance 8-8
recirculation 8-5
saturation calculation 8-6
solubility 8-5
specifying 8-4
supersaturation 8-6
Cyclone
design calculations 8-28
diameter calculation 8-31
dimension ratios 8-31
Versi on 10
Cyclone (continued)
dimensions 8-28, 8-32
efficiency correlations 8-29
geometry 8-32
Leith and Licht correlation 8-29
operating ranges 8-29
overview 8-27
pressure drop 8-30
rating calculations 8-28
Shepherd and Lapple correlation 8-29
solids loading correction 8-34
specifying 8-28
vane constant 8-32
D
Darcy correlation
Pres-Relief 10-12
Decanter model
Gibbs free energy 2-10
KLL coefficients 2-10
liquid phases 2-10
liquid-liquid distribution coefficients 2-10
overview 2-8
phase-splitting methods 2-10
separation efficiencies 2-11
solids entrainment 2-11
specifying 2-9
Decanters
CCD 8-64
Decanter model 2-8
Flash3 2-5
RadFrac 4-18, 4-29
Design mode
RateFrac 4-74
Design mode convergence
RadFrac 4-26
Design specification convergence
MultiFrac 4-44
DIERS calculations
Pres-Relief 10-18
Distillation
Distl 4-6
DSTWU 4-3
MultiFrac 4-30
RateFrac 4-62
SCFrac 4-8
Distl
Edmister approach 4-6
overview 4-6
specifying 4-7
DSTWU
Gillilands method 4-3
overview 4-3
reflux ratio 4-3
specifying 4-4
Underwoods method 4-3
Winns method 4-3
Dukler correlation
Pipe model 6-37
Pipeline 6-48
Pres-Relief 10-12
Dupl
overview 7-4
specifying 7-5
Dynamic scenario algorithm
Pres-Relief 10-19
E
Eaton correlation
Pipe model 6-38
Pipeline 6-49
Edmister approach
Distl 4-6
Efficiencies
Compr 6-12
MCompr 6-16, 6-17
RadFrac 4-20
Electrostatic precipitators
ESP 8-40
Emergency relief vents (ERV)
Pres-Relief 10-15
Equilibrium constants
REquil 5-9
RGibbs 5-13
Equilibrium reactors
REquil 5-8
RGibbs 5-10
ESP
gas velocity 8-41, 8-44
operating range 8-41
overview 8-40
particle separation 8-42, 8-44
Versi on 10
ESP (continued)
power requirement 8-44
pressure drop 8-43
specifying 8-41
Ethylene plant primary fractionators
MultiFrac 4-30
PetroFrac 4-48
Evaporators
Flash2 2-2
Flash3 2-5
Exchanger configuration
HeatX 3-11
Exchanger geometry
HeatX 3-5
Extract
overview 4-87
specifying 4-88
F
FabFl
calculation options 8-23
filtering time 8-24
overview 8-23
resistance coefficients 8-25
specifying 8-23
Fabric filters
FabFl 8-23
Fair method
Feed furnaces
PetroFrac 4-54
Feed stream conventions
RateFrac 4-68
Feed streams
PetroFrac 4-53
Film coefficients
HeatX 3-10, 3-15
Filter model
filter cake characteristics 8-57
overview 8-56
pressure drop 8-58
specifying 8-56
Filters
CFuge 8-52
FabFl 8-23
Filter model 8-56
Flanigan correlation
Pipe model 6-38
Pipeline 6-50
Pres-Relief 10-12
Flash tables
zone analysis 3-21
Flash2
electrolytes 2-4
overview 2-2
solids 2-4
specifying 2-3
Flash3
electrolytes 2-6
overview 2-5
solids 2-6
specifying 2-6
streams 2-5
Flashes
Flash2 2-2
Flash3 2-5
Flexitrays
values A-11
Float valve trays
values A-11
Fractionators
PetroFrac 4-48
Free-water calculations
MultiFrac 4-46
PetroFrac 4-60
RadFrac 4-20
RateFrac 4-74
FSplit
overview 1-5
specifying 1-6
G
Gas-solid separators
Cyclone 8-27
ESP 8-40
FabFl 8-23
VScrub 8-36
General purpose valves
Pres-Relief 10-13
Versi on 10
Gibbs free energy
Decanter model 2-10
REquil 5-9
RGibbs 5-10
Gillilands correlation
DSTWU 4-3
Glitsch Ballast method
GPSA method
Compr 6-10
MCompr 6-15
H
Hagedorn-Brown correlation
Pipe model 6-37
Pipeline 6-49
Hardgrove grindability index (HGI)
Crusher 8-14, 8-18
Hazen-Williams method
Pipe model 6-40
Pipeline 6-52
Heat exchangers
Aerotran 3-26
computational structure 3-21
equations 3-8
Heater model 3-2
HeatX 3-5
Hetran 3-23
MHeatX 3-19
multistream 3-19
zone analysis 3-21
Heat transfer coefficient
HeatX 3-9
Heater model
electrolytes 3-4
overview 3-2
solids 3-4
specifying 3-3
Heaters
Heater model 3-2
MultiFrac 4-38
RadFrac 4-17
RateFrac 4-73
Heat-interstaged columns
MultiFrac 4-30
HeatX
baffle geometry 3-13
electrolytes 3-17
exchanger configuration 3-11
HeatX (continued)
exchanger geometry 3-5
film coefficients 3-10, 3-15
heat transfer coefficient 3-9
log-mean temperature difference 3-8
model correlations 3-15
nozzle geometry 3-15
option sets 3-17
overview 3-5
pressure drop 3-13, 3-14, 3-15
pressure drop calculations 3-10, 3-15
rating calculations 3-5, 3-6, 3-7, 3-8, 3-9
shell-side film coefficient 3-13
solids 3-17
specifying 3-6
streams 3-6
TEMA shells 3-11
tube geometry 3-14
tube-side film coefficient 3-14
zone analysis 3-5
HETP
packings calculations A-12
RateFrac 4-75
Hetran
overview 3-23
solids 3-25
specifying 3-24
Hughmark method
Pipe model 6-37
Pipeline 6-48
HyCyc
dimension ratios 8-49
dimensions 8-50, 8-51
feed splitting 8-48
geometry 8-50
overview 8-45
particle velocity 8-49
pressure drop correlation 8-50
rating 8-46
sizing 8-46
solids separation 8-45
specifying 8-46
velocity correlation 8-49
Versi on 10
Hydraulic turbines
Pump model 6-2
Hydrocyclones
HyCyc 8-45
I
Inside-out algorithms
MultiFrac 4-43
RadFrac 4-26
Isentropic compressors
Compr 6-9, 6-12
MCompr 6-13
Isentropic turbines
Compr 6-9
MCompr 6-13
K
Kettle reboilers
RadFrac 4-16
Knock-out drums
Decanter model 2-8
Flash2 2-2
Flash3 2-5
L
Leith and Licht correlation
Cyclone 8-29
Liquid-liquid extraction
Extract 4-87
Liquid-solid separators
CFuge 8-52
Filter model 8-56
HyCyc 8-45
LNG exchanger
MHeatX 3-19
Lockhart-Martinelli correlation
Pipe model 6-37
Pipeline 6-49
Pres-Relief 10-12
Log-mean temperature
HeatX 3-8
M
Manipulators
ClChng 7-6
Dupl 7-4
Manipulators (continued)
Mult 7-2
MCompr
ASME method 6-15
brake horsepower 6-17
flow coefficient 6-19
GPSA method 6-15
head coefficient 6-18
isentropic efficiency 6-16
mechanical efficiency 6-17
Mollier method 6-15
overview 6-13
parasitic pressure loss 6-17
polytropic efficiency 6-16
specific diameter 6-18
specific speed 6-18
specifying 6-14, 6-15
MHeatX
computational structure 3-21
electrolytes 3-22
flash tables 3-21
LNG exchanger 3-19
overview 3-19
solids 3-22
specifying 3-20
zone analysis 3-19, 3-20, 3-21
Mixer model
overview 1-2
specifying 1-3
Mixers
Heater model 3-2
Mixer model 1-2
Model correlations
HeatX 3-15
Mollier method
Compr 6-10
MCompr 6-15
Mult
overview 7-2
specifying 7-3
MultiFrac
algorithms 4-43
connecting streams 4-36
convergence algorithms 4-42, 4-43
design mode 4-42
design specification convergence 4-44
efficiencies 4-41
ethylene plant primary fractionator 4-30
Versi on 10
MultiFrac (continued)
feed stream conventions 4-35
flow rate 4-38, 4-42
flow ratio 4-40
free-water calculations 4-46
heaters 4-38
initialization methods 4-45
Murphree efficiency 4-41
Newton algorithm 4-44
overview 4-30
packings 4-47
property methods 4-46
rating mode 4-42
solids 4-46
specifying 4-33, 4-34
stream definitions 4-34
streams 4-32, 4-33, 4-35, 4-36, 4-42
sum-rates algorithm 4-43
trays 4-47
vaporization efficiency 4-41
Multistage fractionation units
MultiFrac 4-30
Murphree efficiency
MultiFrac 4-41
PetroFrac 4-57
RadFrac 4-21
RateFrac 4-65, 4-75
N
Napthali-Sandholm algorithm
RadFrac 4-26
Nested convergence
RadFrac 4-27
Newton algorithm
MultiFrac 4-44
RadFrac 4-22, 4-26
RateFrac 4-76
Nonequilibrium fractionation
RateFrac 4-62
Nozzle geometry
HeatX 3-15
O
Oliphant method
Pipe model 6-39
Pipeline 6-51
Orkiszewski correlation
Pipe model 6-37
Pipeline 6-49
P
Packings
calculations A-12
capacity calculations A-13
liquid holdup calculations A-16
MultiFrac 4-47
PetroFrac 4-61
pressure profile A-17
RateFrac 4-70
rating A-12
sizing A-12
specifying A-1
Stichlmair correlation A-16
types A-1, A-12, A-13
Panhandle methods
Pipe model 6-40
Pipeline 6-51
Particle separation
ESP 8-42, 8-44
PetroFrac
condensers 4-51
convergence algorithms 4-58
design mode 4-59
efficiencies 4-57
ethylene plant primary fractionator 4-48
feed furnace 4-51, 4-54
feed streams 4-53
liquid runback 4-56
main column 4-50, 4-51
overview 4-48
packings 4-61
pumparounds 4-56
rating mode 4-59
reboilers 4-51
side strippers 4-51, 4-57
solids 4-61
specifying 4-51
streams 4-49
trays 4-61
vaporization efficiency 4-57
Versi on 10
Petroleum refining fractionation
MultiFrac 4-30
PetroFrac 4-48
Petroleum/petrochemical applications
RadFrac 4-22
Physical properties
columns A-17
HeatX 3-17
Physical property methods
RateFrac 4-74
Pinch points
estimating 3-21
Pipe model
AGA method 6-39
Angel-Welchon-Ros correlation 6-38
Beggs and Brill correlation 6-37
Beggs and Brill correlation parameters 6-38
closed-form methods 6-39
Design-Spec convergence loop 6-34
downstream and upstream integration 6-33
Dukler correlation 6-37
Eaton correlation 6-38
erosional velocity 6-34
fittings modeling 6-35
Flanigan correlation 6-38
flash options 6-32
fraction factor correlations 6-35
Hagedorn-Brown correlation 6-37
Hazen-Williams method 6-40
holdup correlations 6-35
Hughmark method 6-37
integration direction 6-33
liquid holdup correlations 6-35
Lockhart-Martinelli correlation 6-37
methane gas systems 6-34
Oliphant method 6-39
Orkiszewski correlation 6-37
overview 6-30
Panhandle methods 6-40
physical property calculations 6-32
pressure drop calculations 6-33
pressure specification 6-31
Slack correlation 6-38
Smith method 6-39
specifying 6-31
stream specification 6-32
two-phase correlations 6-35
valve modeling 6-35
Weymouth method 6-39
Pipeline
AGA method 6-51
Angel-Welchon-Ros correlation 6-49
Beggs and Brill correlation parameters 6-50
closed-form methods 6-50
Design-Spec convergence loop 6-46
downstream and upstream integration 6-45
Eaton correlation 6-49
erosional velocity 6-46
Flanigan correlation 6-50
fraction factor correlations 6-47
Hagedorn-Brown correlation 6-49
Hazen-Williams method 6-52
holdup correlations 6-47
Hughmark method 6-48
integration direction 6-45
liquid holdup correlations 6-47
methane gas systems 6-47
nodes and segments 6-44
Oliphant method 6-51
Orkiszewski correlation 6-49
overview 6-42
Panhandle methods 6-51
physical property calculations 6-45
pressure drop calculations 6-45
Smith method 6-51
specifying 6-43
stream specification 6-44
two-phase correlations 6-47
Weymouth method 6-51
Pipes
Pipe model 6-30
Pipeline 6-42
Piping system
Pres-Relief 10-11
Plug flow reactors
RPlug 5-21
Polytropic compressors
Compr 6-9, 6-11
MCompr 6-13
Pres-Relief
3% rule 10-8
97% rule 10-8
calculation methods 10-23
Versi on 10
Pres-Relief (continued)
capacity runs 10-6
code compliance 10-6
convergence methods 10-23
credit factors 10-4
Darcy correlation 10-12
data tables 10-1210-16
DIERS calculations 10-18
disengagement options 10-18
dynamic scenarios 10-2, 10-7, 10-16, 10-18, 10-19
energy input calculations 10-4
fire scenario 10-3
flow equations 10-20
heat exchanger shell 10-17
heat flux scenario 10-5
insulation credit factor 10-24
manufacturers' tables 10-1210-16
nozzle flow equation 10-22
overview 10-2
pipe diameters 10-12
pipe flow equation 10-20
pipe specifications 10-11
reactions 10-9
relief system 10-10
relief system flow rating scenario 10-5
relief valve flow rating scenario 10-6
rupture disks 10-15
safety relief valves 10-14
sample solution 10-19
scenarios 10-3
sizing rules 10-7, 10-9
specifying 10-2, 10-10, 10-11
spheres 10-17
steady-state scenarios 10-6
stop criteria 10-18
streams 10-7
user-specified vessel 10-17
valve cycling 10-16
valve types 10-10, 10-13
vents 10-15
vessel geometry 10-16
vessel head types 10-17
vessel jacket 10-17
wetted area calculations 10-4
X% rule 10-8
Pressure changers
Compr 6-9
MCompr 6-13
Pipe model 6-30
Pressure changers (continued)
Pipeline 6-42
Pump model 6-2
Valve model 6-20
Pressure drop
HeatX 3-13, 3-14, 3-15
Pressure drop calculations
HeatX 3-10, 3-15
Pressure drop models
Pipe model 6-30
Pipeline 6-42
Pressure relief systems
Pres-Relief 10-2
Pump model
head coefficient 6-7
net positive suction head (NPSH) 6-4
overview 6-2
specific speed 6-5
specifying 6-3
suction specific speed 6-6
Pumparounds
RadFrac 4-18
Pumps
Heater model 3-2
Pump model 6-2
R
RadFrac 4-23
absorbers 4-23
algorithms 4-22
azeotropic distillation 4-22
column configuration 4-13, 4-16
convergence algorithms 4-22, 4-25
convergence methods 4-26, 4-27, 4-28
coolers 4-17
decanters 4-18, 4-29
design mode 4-24
design mode convergence 4-26
design specifications 4-27
efficiencies 4-20
feed streams 4-14
heaters 4-17
inside-out algorithms 4-26
kettle reboilers 4-16
Napthali-Sandholm algorithm 4-26
Versi on 10
RadFrac (continued)
Newton algorithm 4-22, 4-26
nonideal systems 4-22
overview 4-11
petroleum/petrochemical applications 4-22
pumparounds 4-18
rating mode 4-23
reactive distillation 4-25
reboilers 4-16
salt precipitation 4-25
simultaneous convergence 4-28
solids handling 4-28
specifying 4-12
stage numbering 4-14
streams 4-12
strippers 4-23
thermosyphon reboilers 4-16
three-phase calculations 4-20, 4-23
two-phase calculations 4-23
UA calculations 4-17
vaporizaton efficiency 4-20
Rate-based modeling
RateFrac 4-62, 4-65
RateFrac
bubble-cap tray column 4-81
Chilton-Colburn analogy 4-77, 4-84
column configuration 4-70
column numbering 4-67
component ratio 4-75
connecting streams 4-70
convergence 4-76
coolers 4-73
correlations 4-76, 4-77
design mode 4-74
efficiencies 4-65, 4-75
equilibrium stages 4-72
feed stream conventions 4-68
Fortran subroutines 4-77
heat transfer coefficients 4-84
heaters 4-73
HETP 4-65, 4-75
interfacial areas 4-76, 4-77, 4-79, 4-81, 4-82
mass transfer coefficients 4-76, 4-77, 4-79, 4-81, 4-82
Newton algorithm 4-76
overview 4-62
packing specifications 4-70
RateFrac (continued)
physical property method 4-74
rate-based modeling 4-65
rating mode 4-74
reactions 4-72
reactive distillation 4-72
segments 4-71, 4-75
side duties 4-73
sieve tray column correlations 4-82
solution times 4-76
specifying 4-64, 4-66, 4-70
stream definitions 4-68
streams 4-63
tray column 4-79
tray column correlations 4-81, 4-82
tray specifications 4-70
utility exchangers 4-73
valve tray column 4-79
Rating mode
RateFrac 4-74
RBatch
batch operation 5-29
cycle time 5-28
mass balances 5-28
overview 5-25
reactions 5-28
specifying 5-26
stop criteria 5-28
temperature controller 5-27
RCSTR
overview 5-16
phase volume 5-17
reaction kinetics 5-17
residence time 5-18
scaling methods 5-19
solids reactions 5-18
specifying 5-17
variable scaling 5-19
Reactions
RateFrac 4-72
Reactive distillation
RadFrac 4-25
Reactors
RBatch 5-25
RCSTR 5-16
REquil 5-8
RGibbs 5-10
RPlug 5-21
RStoic 5-2
RYield 5-6
Versi on 10
Reboilers
PetroFrac 4-51
RadFrac 4-16
Relief devices
Pres-Relief 10-10
REquil
equilibrium constants 5-9
Gibbs free energy 5-9
net heat duty 5-8
overview 5-8
solids 5-9
specifying 5-9
streams 5-8
RGibbs
chemical equilibrium 5-12
overview 5-10
phase equilibrium 5-12, 5-13
reactions 5-14
restricted chemical equilibrium 5-13
solids 5-14
specifying 5-11
Rigorous distillation
MultiFrac 4-30
PetroFrac 4-48
RadFrac 4-11
RateFrac 4-62
Rigorous extraction
Extract 4-87
RPlug
coolant 5-23
overview 5-21
reactions 5-24
solids 5-24
specifying 5-22
RStoic
heat of reaction 5-3, 5-4
overview 5-2
product selectivity 5-3, 5-4
specifying 5-3
stream specifications 5-3
RYield
calculation types 5-7
heat duty specification 5-7
overview 5-6
specifying 5-7
yield distribution 5-7
S
Salt precipitation
RadFrac 4-25
SCFrac
crude units 4-8
overview 4-8
specifying 4-9
vacuum towers 4-8
Screen
operating levels 8-20
overview 8-19
screen size correlation 8-21
selection function 8-20
separation strength 8-20
specifying 8-19
Sep
inlet pressure 2-13
outlet stream conditions 2-13
overview 2-12
specifying 2-13
Sep2
inlet pressure 2-16
outlet stream conditions 2-16
overview 2-14
specifying 2-15
substreams 2-15
Separators
Decanter model 2-8
Flash2 2-2
Flash3 2-5
Sep 2-12
Sep2 2-14
Shell heat exchangers
Hetran 3-23
Shell-side film coefficient
HeatX 3-13
Shepherd and Lapple correlation
Cyclone 8-29
Shortcut distillation
Distl 4-6
DSTWU 4-3
SCFrac 4-8
Simultaneous convergence
RadFrac 4-28
Sizing recommendations
Pres-Relief 10-9
Versi on 10
Slack correlation
Pipe model 6-38
Pipeline 6-49
Pres-Relief 10-12
Smith method
Pipe model 6-39
Pipeline 6-51
Solids
Crystallizer 8-3
Flash2 2-4
Flash3 2-6
Heater model 3-4
MHeatX 3-22
RGibbs 5-14
Solids crushers
Crusher 8-13
Solids separators
CFuge 8-52
Crusher 8-13
Cyclone 8-27
ESP 8-40
FabFl 8-23
Filter model 8-56
HyCyc 8-45
Screen 8-19
VScrub 8-36
Solids washers
CCD 8-64
SWash 8-61
Splitters
FSplit 1-5
Sep 2-12
Sep2 2-14
SSplit 1-8
SSplit
overview 1-8
specifying 1-8
Stichlmair correlation
packings calculations A-16
Stoichiometric reactors
RStoic 5-2
Stream classes
changing 7-6
Stream definitions
RateFrac 4-68
Stream manipulators
ClChng 7-6
Dupl 7-4
Mult 7-2
Stream mixers
Mixer model 1-2
Stream multiplication
Mult 7-2
Stream pressure changers
Pump model 6-2
Stream splitters
FSplit 1-5
SSplit 1-8
Streams
combining 1-8
Flash3 2-5
splitting 2-12, 2-14
Strippers
MultiFrac 4-30
RadFrac 4-23
RateFrac 4-62
Substream splitters
SSplit 1-8
Sum-rates algorithm
MultiFrac 4-43
SWash
bypass fraction 8-63
mixing efficiency 8-62
overview 8-61
specifying 8-62
T
TEMA shells
HeatX 3-11
Thermosyphon reboilers
RadFrac 4-16
Three-phase calculations
RadFrac 4-20
Trays
Bolles method A-8
bubble cap A-9
downcomer specifications A-3
Flexitrays A-11
float valve A-11
flooding calculations A-8
foaming calculations A-11
MultiFrac 4-47
PetroFrac 4-61
pressure profile A-17
RateFrac 4-70
rating A-2, A-8
sizing A-2, A-8
specifying A-1
types A-1
Versi on 10
Tube geometry
HeatX 3-14
Tube heat exchangers
Hetran 3-23
Tube-side film coefficient
HeatX 3-14
Turbines
Compr 6-9
MCompr 6-13
Pump model 6-2
U
Underwoods method
DSTWU 4-3
Unit operation models
user-supplied 9-2, 9-4
User model
overview 9-2
specifying 9-3
User2
overview 9-4
specifying 9-5
V
Vacuum filters
Filter model 8-56
Vacuum towers
SCFrac 4-8
Valve model
calculation types 6-20
cavitation index 6-29
characteristic equation 6-26
choked flow 6-28
overview 6-20
piping geometry factor 6-26
pressure drop calculation 6-20, 6-28
pressure drop ratio factor 6-22
pressure recovery factor 6-23
specifying 6-20
Valves
cycling 10-16
Heater model 3-2
Pipe model 6-35
Valves (continued)
safety relief 10-14
types used in Pres-Relief 10-10, 10-1310-16
Valve model 6-20
Vaporization efficiency
MultiFrac 4-41
PetroFrac 4-57
RadFrac 4-20
Vents
Pres-Relief 10-15
Venturi scrubbers
VScrub 8-36
VScrub
overview 8-36
pressure drop 8-38
rating 8-37
sizing 8-37
specifying 8-37
W
Weymouth method
Pipe model 6-39
Pipeline 6-51
Winn's method
DSTWU 4-3
Y
Yield reactors
RYield 5-6
Z
Zone analysis
HeatX 3-5
MHeatX 3-19, 3-20, 3-21
Versi on 10

Aspen Plus Reference Manual, Unit Operation Models

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Unit Operation Models

, Aspen Custom Model er

are ei ther regi stered trademarks, or trademarks of Aspen

are trademarks of Koch Engi neeri ng Company,

i s a trademark of Rai nbow Technol ogi es, I nc.

Rate-based distillation Performs rigorous rating and design for

Recovery of any components groups Set of product streams, including sidestreams

Ratio or difference of any pair of

See ASPEN PLUS User Gui de.

= Cal cul ated val ue

One whose flow is fixed

A terminal stream (vapor

Duty can default to 0 if necessary.

Enter zero for heat duty if heater is absent.

Recovery of any component groups Set of product streams

Ratio or difference of any pair of properties in

See ASPEN PLUS User Gui de.

Recovery of any components group Set of product streams

Difference of any pair of Prop-Set properties Pair of product streams

Express recovery as a fraction of the same components in a subset of feed streams.

See ASPEN PLUS User Gui de, Chapter 28.

Enter zero for heat duty if heater is absent.

Recovery of any component groups Set of product streams

Flow of any component groups Internal stream or set of product streams

Ratio or difference of any pair of

See ASPEN PLUS User Gui de, Chapter 28.

Chan and Fair (1984)

Grester et al. (1958)

+ + 0 776 4 567 0 2377 104 85

You can specify inert components by setting the fraction to 1.

The basi c compressor rel ati on i s:

For expansi on:

The basi c compressor rel ati on i s:

Uni t Operati on Model s 6-17

= Fl ow coeffi ci ent of the val ve i nstal l ed i n a strai ght pi pe of the

= Val ve fl ow coeffi ci ent

See ASPEN PLUS User Model s.

See ASPEN PLUS User Model s.

See ASPEN PLUS User Model s.

See ASPEN PLUS User Model s.

See ASPEN PLUS User Model s.

where V / q i s the crystal resi dence ti me.

Design Separation efficiency Liquid flow rate

= Vi scosi ty of the gas

8-48 Uni t Operati on Model s

O = Speci fi c cake resi stance at uni t pressure drop

Uni t Operati on Model s 8-59

You must specify F

See Vessel I nsulation Credit Factor, this chapter.

whi ch can be re-wri tten (noti ng that u = G ):

Koch Fl exi tray

Nutter Fl oat Val ve

Norton I ntal ox Structured Packi ng

V = Densi ty of vapor to packi ng

L = Densi ty of l i qui d from packi ng

Norton Vendor procedure

Koch Vendor procedure

Not specified Eckert GPDC

Glitsch Grid Vendor procedure

Norton Intalox Structured Packings Vendor procedure

Sulzer BX, CY, Mellapak, and Kerapak Vendor procedure

Koch Flexipac, Flexeramic, and Flexigrid Vendor procedure

Goodloe, Bulletin 520A (Dallas: Glitsch, I nc., 1981).

Norton Company, private communication, 1992.