Computer Assisted Process

Design---HYSYS
Bo Hu

Introduction
HYSYS is only one process simulation program out of a number.
Steady State Processes
ASPEN Plus, HYSYS.Plant, CHEMCAD, PRO/II,
Batch Processes
BATCH PLUS, SUPERPRO DESIGNER
Computer codes : Algorithms written in FORTRAN or C.
Purpose for simulators :
To solve material and energy balances
To allow for graphical user design of processes and connections
To govern how data is input and to check for
To iterate to solution and allow for optimization
To allow for data output in the form of PDF files (for printing).

Principles of Steady-State
Flowsheet Simulation
Process software allows interim calculation of unknown P,T, and flow rates during process synthesis
Process flowsheets are the language of chemical processes
Knowns - Calculate using model, equations, and process variables Unknowns
(Stream pressure, temperature, flow rate, composition, surface area, valve settings,
geometrical configurations...)
Material balances, material and energy balances, equipment sizing, profitability analysis.
Equation solving algorithms become more complex as new variables are introduced.
Conventional process equipment Equations do not differ amongst chemical processes.
Physical and thermodynamic properties and chemical kinetics constants differ.
Problem solving algorithms use FORTRAN or C (Heart of process simulators)
Libraries of models and subroutines used.
Subroutines or models are referred to as procedures, modules, or blocks.
Distinguish PROCESS FLOWSHEET and SIMULATION FLOWSHEET
Process flow sheet Icons representing process units with arcs to represent the flow of materials to
and from the units.
Simulation flow sheet Simulation units represent computer programs with arcs that represent the
information flows between units.

Principles of Steady-State
Flowsheet Simulation
Labeling conventions differ between ASPEN PLUS, HYSYS, CHEMCAD, and PRO/II.
Unit name , Model Name

Simulation unit unique name

M1
MIXER

Name of subroutine or model (or block)

HYSYS model names are tabulated separately

ASPEN PLUS
Mathematical convergence simulator (Dashed-line rectangle) = Adjusts stream variables in the
information recycle loop (iterative calculation necessary).
In HYSYS, the user positions the recycle convergence unit.
CHEMCAD and PRO/II the convergence unit does exist but it is hidden.
Process flowsheet to Simulation flow sheet Replace the process units with corresponding
subroutines.
Approximate models vs. Rigorous models (Move between them as process synthesis progresses)

Principles of Steady-State
Flowsheet Simulation
Need to become familiar with the assumptions of the models provided by the simulators
See manuals for the simulator and model assumptions.
Table 4.1 Summarizes a selection of process subroutines used by the 4 program codes.
MIXER is modeled as a specific unit, even though this is often done in the pipeline.
FSPLIT (ASPEN PLUS), Tee (HYSYS), DIVI & SPLITTER (CHEMCAD and PRO-II) is needed to split a
flow into two streams.
Stream multipliers (fictitious streams).
Steady state simulators do not solve time-dependent equations.
Operation subroutines simulates process units steady state operation
Cost subroutines estimates sizes and costs of process units
Convergence subroutines converges recycle computations
Control subroutines alters equipment parameters
ASPEN Principles of Flowsheet Simulation Creating a Simulation Flowsheet
HYSYS Principles of Flowsheet Simulation Getting started in HYSYS.
ASSUMPTION : Streams = one or more solution phases, in phase equilibrium
Exceptions are non-conventional components e.g. solid phases, coal, ash, wood.

Principles of Steady-State
Flowsheet Simulation
Streams :
Degrees of freedom Vapor-liquid equilibrium for each stream C+2 degrees of freedom.
C = number of chemical specie.
Specify C species flow rates and two intensive variables (temperature, pressure, vapor fraction
or enthalpy).
Temperature and Pressure specified Calculate all the intensive properties via vapor-liquid
equilibrium equations.
Pressure and vapor fraction specified Remaining intensive properties are computed
Bubble point and dew point temperatures are computed by specifying vapor fraction = zero
and unity respectively.
REFER TO THEORY OF PHASE EQUILIBRIA
Number of equations must equal the number of variables for solution

Principles of Steady-State
Flowsheet Simulation
Example 4.1 Consider a cooler in Figure 4.5 in which the binary stream S1 contains benzene and
toluene at a vapor fraction of phi1=0.5 is condensed by removing heat, Q. Carry out a degrees
of freedom analysis
SOLUTION : F1xB1=F2xB2

F1xT1=F2xT2
F1h1+Q=F2h2
F is the molar flow rate
x is the mole fraction of a specie
h is the enthalpy
P is the pressure
phi is the vapor fraction
i=stream
Number of Equations = 7
Number of Variables = 13
Number of inputs = 13-7
Which are F1, P1, phi1, xB1 and P2 and Q

S1

S2
hi=hi[Pi, phii, xi], i=1,2
xTi=1-xBi, i=1,2

Principles of Batch Flowsheet Simulation

Batch Process Simulation
BATCH PLUS produced by Aspen Technology, Inc.
and SUPERPRO DESIGNER produced by Intelligen Inc.
tPA Tissue Plasminogen Activator production is a batch process.
Throughput is small, Continuous processing is difficult.
When using multiple products switching between products is easier if using
batch processing.
Discussed in more detail in Chapter 12
Material and Energy Balances
Prepares Operating Schedule in the form of a Gantt Chart.
Equipment and operating costs estimated and profitability measures
computed.
Process and Simulation Flowsheets
Equipment models
Combined Batch and Continuous Processes
Example 4.5 tPA Cultivators

Summary

Simulation flow sheet beginning with a process flow sheet.

Be familiar with ASPEN PLUS and HYSYS.Plant
Modules and subroutines for units form the basis for simulations.
Recycle Loops make solution complex.
Degrees of freedom analysis on material and energy balance equations
allows user to determine how many input data variables one needs to
specify.
Subroutines are structured to allow for forward and backward input of
information.

Assignment
1.
2.

Lab assignment: work on HYSYS tutorial chapter 3

Homework assignment: Make (or choose) a decision on your alternative
solutions and Develop a process flow chart of your project