PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares ASPEN HYSYS 2013 HYSYS WORKBOOK 2013 By: Eng. Ahmed Deyab Fares eng.a.deab@gmail.com — adeyab@adeyab.com A Alimed Deyab Fares By: Eng. Ahmed Deyab Fares — Mobile: 002-01227549943 - Email: adeyab@adeyab.com | 1PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Flash Separation We have a stream containing 15% ethane, 20% propane, 6npoubylane and 5% n-butane at 50°F and atmospheric pressure, ® rate of 1001bmole/hr. This stream is to be compressedftog$0 pata and then cooled to 32°F. The resulting vapor and liquid are tbe separates the two product streams. Neglect the fe drop ins condenser. > ° * Fluid pkg: PR @ ; * What are the flow rat@yand colfipesitions off streams? Component or Liquid Ethane ‘Propane T-Butane By: Eng. Ahmed Deyab Fares Mobile: 002-01227549943 — - Email: adeyab@adeyab.comPROCESS SIMULATION CASES 2013 A Ahmed Deyab Fares Propane Refrigeration Cycle A Refrigeration cycle utilizes propane as the worki is used in the Liquefaction of the NG. Propane is fed to an eygp eater) the pressure drop~5 kPa, where it absorbed 1.50cH from the NG an leaves at the dew point (Vapor Fraction=1.0) at T= -RC. The outp the evaporator is then compressed sao efficiency and then it's condensed to reject heat. 1 Condenser, pressure drop of 30 kPa, and leaves as, liquid at a, the propane passes through a J-T return ’e of the Evaporator. @ oO Fluid Pkg: Peng Rob ‘ Calculate: Pressure of the evapor, KPa. Flow rate of propane rr Valve pressure di Temperature ive outlet ing By: Eng. Ahmed Deyab Fares — Mobile: 002-01227549943 - Email: adeyab@adeyab.com | 3PROCESS SIMULATION CASES 2013 A Alimed Deyab Fares Refrigerated Gas Plant This tutorial will model a natural gas processing facili fises propane refrigeration to condense liquids from the fe! The feed stream enters an inlet separator, wi es the free liquids. Overhead gas from the Separator is fe e Chiller wher is cooled to -20°G, which will be modeled simply as a Cooler (Pre: Drop=35 kPa). The cold stream is then a. a lowtemp@ratlre separator (LTS). Overhead gas from is fed to the beater (Pressure drop=5kPa) where it is X= 10°C Sales Cas Specifications. @ Feed Stream: oC Temperature Pres Midler Flow Rate 45°C 0 kPa 4a@kgmolejh Component le nt Mole Ny 0.0066 jutane 0.0101 Hse SY coor cons co, 0.0 n-Pentane 0.0027 Methan On, n-Hexane 0.0006, @ H,0 0.0000 0.0413 C7+(NBP=110°C) 0.0001 0.0068 inson + Gileulate the duty rejected from the chiller + Gileulate the duty Absorbed inside the Heater By: Eng. Ahmed Deyab Fares — Mobile: 002-01227549943 - Email: adeyab@adeyab.com , 4Eng PROCESS SIMULATION CASES 2013 B i imed Deyab Fares ine cepvap a rehig *" La wriktop i Subsequently, the design is modified to r& represented in Chiller & Heater duties, before the Chiller where the overhea Shell side Pressu; - No heat losses it Choose Wei LTS Liquid By: Eng. Ahmed Deyab Fares — Mobile: 002-01227549943 - Email: adeyab@adeyab.com | >PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Heat Exchanger Rating ‘The pressure drops on both sides Gy: fanger ross ted; this will allow HYSYS to cale parameters. + Tube Lengt + Number ot 300 + Tube Bitch’ + Bal The dimensions of the ¢: crane; " ~@Z + All other p; ers are the HYSYS default values gS me D>... of the Sales Gas using this exchanger? By: Eng. Ahmed Deyab Fares —_— Mobile: 002-01227549943 - Email: adeyab@adeyab.com , ©PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Balance & Adjust Operations er) peeeerer ry To duplicate the composition of the SalesGa: order to calculate its dew point temperatures specification pressure. Adjust To determine the required LTS temper: a specified Balance The next step is to check the Sales Gas stream to if it meets a cd point temperature specification, This is ti 0 liquids fornygl the transmission line, Atypical pipeline wae. oO at 6000 kPa, which will be used for thi le. CG Now we need first to calculate the the tem perature of this streay IC Dewpoint eters tab) Mole Pressure off a for the stream HC Dewpoint. ae What the dewpai lated from H€ Dewpoint stream? required “Oy -15°C, is the current dewpoint higher or lower? By: Eng. Ahmed Deyab Fares a Mobile: 002-01227549943 - Email: adeyab@adeyab.com | 7PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Distillation (1) We need to separate a mixture of five paraffins into light qpehife fraction by using a distillation column with 12 ideal sta; I reflux condenser, and a reboiler. The feed stream (1000 Ibmol/hr) consists of 3% (mol@p) ethane, 20 ays conn ie propane, 37% n-butane, 35% n-pentanea 250 psia, which enters the column on th top. The condenserand reboiler pres: Calculate: Thec rand the; OF after modification Col ser Temp jer Temp Oy o) By: Eng. Ahmed Deyab Fares — Mobile: 002-01227549943 - Email: adeyab@adeyab.com | 8PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Distillation (2) 3700 kg/hr mixture of tetrahydrofuran & toluene (44 mass% and 140 kPa is to be separated by distillation to get each oft Rtyn with purity of 99.5 mass% of THF & 94 mass% of Tolue! o- volatile component). * Use Wilson fluid package The column specifications are: (eo) 2 . The condenser & reboiler pressiife are 103 kPa . The condenser works on © Number of stages = 4g © Feed enters from aff Calculate: The reflux oy the specified conditions. Reflux. ist te ne kGme hr By: Eng. Ahmed Deyab Fares Mobile: 002-01227549943 — - Email: adeyab@adeyab.comPROCESS SIMULATION CASES 2013 A Ahmed Deyab Fares Two Stage Compression A stroam of N.Gis fed toa separator at 35°C and 1725 kPa with a flowgplagespit000 Ibaci/hr where free condensates are separated. ‘The gas is then comprgs¥@tbfo 3450 kPa with adiabatic eficieney of 75% in a cantrifigal compressog, Th eonifressed gas is then cooled to 50°C before entering a second separator white liquid is th sent to a valve (delta P= 1725 kPa) and recycled back to the Mgt separator, The o' gas is fed to a second compressor where the pressure isadoubled and then coolihto 40°C before entering the last separator where the o1 is sent to a sey (delta P=3450 kPa) and reeyeled back to the seco 5. Notes: e - Neglect the pressure drop insi: coo} ~ Use Mixer to mix the rey, ith the origi - EPKg: PR [Component ole wy 04 i-Butane --- 00652 CO) @y n-But: 0.0573 Methane 069 oe 0.0515 Ethane 0.1451 sntane 0.0431 ees ree By: Eng, Ahmed Deyab Fares —_— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com | 10PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Compressor Curves eal = Using compressor curves in your HYSYS simulation al accurately model existing plant equipment. You can jne if an existing compressor is able to meet the specific: ur process. Using compressor curves allows HYSYS 18@gffeulate heads an efficiencies that are dependent on the flow rate. If the*flow rate thregigh’ (single pressure Oo Tow rate is C to ale e the compressor is known to be consta efficiency can be supplied, If, however change, using a compressor curve will@lleW HYSYS to : new heads and efficiencies based on the How rate. This results in greater accur: lation, a HYSYS to more closely model actual pment. Simulation, y s provides you with a set r= which iow Gkists ia e able to achieve the outlet ill you have to add a third stage of | 3360 By: Eng. Ahmed Deyab Fares —_— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com | 11PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Sour Water Stripper Sour water feed stream (328451.13 kg/hr) contains 0.7 Yad anole NH; and 98.8%mole H,O at 100°F & 40 oe through a feed/effluent exchanger where it recovers heat fj O- bottoms strearn (Stripper Bottorns). The sour water feed the tube side of, exchanger to be heated to 200 °F while the stripped bollom enters th botifpshell side “© e-heated sor side. A pressure drop of 10 psi takes place (Use weighted model for the exchanger), is then fed to a stripper (Distillation f The pre-heated S86 water stream enters on the 3" tray of an tillation a reboiler and a fill reflux condenser. The condenser, = 28.7 psia while the stripper reboile =32.7 psia. atio 10 (molar basis) and Overhead of 352 he tower bottoms exchanges heat with th ing feed Fluid PackasedEPgRcbineon Calculate, oO a) The bottom pro« erature CC). b) lo the Effluent stream. ole of NH: luent. +s S ¥ 12 By: Eng. Ahmed Deyab Fares — Mobile: 002-01227549943 — - Email: adeyab@adeyab.comEng PROCESS SIMULATION CASES 2013 B Aimed Deyab Fares Absorption CO) is absorbed into propylene carbonate in an absorber ~< ; the inlet gas stream (Top stage Inlet) is 20 mol% CO, lance is methane. The gas stream flows at a rate of . psin & Reboiler pressure =335 psia @ = Top ong = -125"F & Reboiler temperature = 80°F = Ovid Prod Rite = 2950 Ibrnolehr (1338 K/h) The design is then modified to ensure that the overhead molar fraction of the methane is 0.96 By: Eng, Ahmed Deyab Fares —_— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com | 15PROCESS SIMULATION CASES 2013 A Alimed Deyab Fares Most of methane is removed from the top of the tower and the bottom stream is pumped to 2790 kpa then it enters to the De+ cr (distillation Colurnn) where most of the ethane in the crude is ‘an overhead product then it is processed to use in different appli ‘The de-ethanizer has the following specifications: oO Connections Name pez No. of Stages 14. Inlet Stream/Stage Condenser Type Overhead Vapour Product D2 Ovhd ® Overhead Liquid Product Bottoms Liquid Outlet Reboiler Duty Energy Streal DC2 RekQ Condenser Duty Energ\jream De2 Pressures Condenser ‘a (395 psia) Condenser Del ‘a (5 psi) Reboiler 2792 kPa (405 psia) Te imates -4°C (25°F) Redie” 95°C (200°F) Specifications Perhead Vapo 320 kgmole/h (700 lbmole/hr) tillate Ri 0 kgmole/h Reflux Rati 2.5 (Molar) The desl modified to ensure that the bottom stream has ratio between Cy/C3 = 0.01 By: Eng. Ahmed Deyab Fares —_— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com | 16PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Then the bottom product is sent to a valve where the pressure of it decrease to 1690 kpa, the outlet flow from the valve is sent t@jagde- propanizer (distillation Column) where most of propane is the top and the heavier hydrocarbons is removed from the ba ‘The specifications of the de-propanizer are: Connections Name De No. of Stages 24 Inlet Streams/Stage 11 CG Condenser Type Tal e Ovhd Licuid Outlet Dist Bottom Liqud Outlet DC3 Bim Reboiler Duty Energy Stre: DC3 Reb.Q Condenser Duty Ener@giream Dc3 Condenser 4 ‘2 (230 psia) Condenser Del 2 (5 psi) Rebciler 55 kPa (240 psia) timates 38°C (100°F) 120°C (250°F) 110 kgmolefh (240 tbmole/hr) By: Eng. Ahmed Deyab Fares — 17 Mobile: 002-01227549943 | - Email: adeyab@adeyab.comPROCESS SIMULATION CASES 2013 A Alimed Deyab Fares Oil Characterization ‘The petroleum characterization method in HYSYS will convert laboratg kes of condensates, erude oils, petroleum cuts and coal-tar liquids into of discrete hypothetical components. These petroleum hypocemponents asis for the property package to predict the remaining thermodyn: ort propertic necessary for fluid modeling. In this example, the Oil Charaeterization option in is used to model 5 oil. The crnde is the feed stock to oil refining proce Bulk Properties of the crude: API Gravity of 29 Light Ends (Mie): rary Methane Ethane Propane i-Butane 0: n-Butane i-Pentani Beco ~12°C (10.4°F) 32°C (90°F) TEC (168°F) 116°C (241°F) 154°C (310°F) 224°C (436°F) 273°C (23°F) 327°C (620°F) 399°C (740°F) ‘50°C (82°F) 490°C (944°F) 516°C (961°F) Sr By: Eng, Ahmed Deyab Fares _— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com | 18PROCESS SIMULATION CASES 2013 A Ahmed Deyab Fares Pre-Heat Train A crude stream at 15°C, 1000 kPa and flowrate of 6*10° kg % jixed with a stream of water at 15°C, 1000 kPa and flowrate g00 kg/hr using a Mixer, the outlet from the mixer is then h through a Heater (Ap=S0 kPa), the heater outlet is fed to fe side of a Shell Tube Heat Exchanger, where it's heated using a Shell Wlet stream haying the same composition as the crude feed str a enters the shi heat exchanger at 180°C, 200 kPa and floygfat@ygP 175m /hr. 6 gas is separated. The oil heated to 175°C throu; to a Preflash (Separati liquid product from, (Pressure drop=: e « @ & + Thev tion ofthe product stream before entering the @ A fe column, = THRGHE side outlet Temperature. - The vapor molar flow rate from the Preflash. By: Eng. Ahmed Deyab Fares —_— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com | 19PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares Gas Gathering There are 4 gas wells, we need to gather the gas from the “we fer it to the plant through pipe lines shown below: is the same: Mole Fraction 0.00405 0.00659 0.00992, 0.00554 0.0225 0.0154 rE] 45 (115) ries re 40 (105) 4136 (800) 425 (935) eer 45 (175) 3450 (500) 375 (625) 35 (95) 575 (1270) 545 (1200) The pipe segments data are given below: By: Eng. Ahmed Deyab Fares —_— Mobile: 002-01227549943 | - Email: adeyab@adeyab.com 20PROCESS SIMULATION CASES 2013 B Ahmed Deyab Fares pone ee er eed Per meters (feet) Change Branch 1 GasWell 1 639 (2095), Branch 2 GasWell 2 (2015) Branch 4 Branch 1&2 90) Branch & Branch 3 & 4, 698 (2077) 77) 4 > 617 (2025) (-52) Branch6 Ge 632.5 (2075) 2 -8 (-25) 76.2 mm (3") 107.6 mm (4) 152 mm (6°) 76.2 mm (3") 152 mm (6") estimation. (Ambient Terperature=15°C) - Calculate the pressure drop and the heat loses inside each pipe. By: Eng, Ahmed Deyab Fares —_ Mobile: 002-01227549943 | - Email: adeyab@adeyab.com 21