PRO/II

ACADEMIC MANUAL Student

Edition

License and Copyright Infor ation

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SIMULA!ION O%ER%IE' SEC!ION 'hat is Si u(ation) * O+er+ie, of PRO/II * Si u(ation Made Easy .ui(ding the Process /(o, Diagra 0 Setting the Input Units of Measure 12 Defining the Co ponents 13 Data 66

Co ponent Properties 14 Se(ecting the !her odyna ic Method 15 Supp(ying Process Strea

Supp(ying Process Unit Operations Data 32 Running the Si u(ation 36 !EC&NICAL RE/ERENCE SEC!ION Using Specification and Define /eatures 3* /(ash Dru 35 %a(+e7 Mi8er7 and Sp(itter Unit

Operations 92 Co pressors 91 &eat E8changers 96 Pu ps 99 $enerating Output 94 On(ine &e(p 43 'or"ing ,ith :ey,ord Input /i(es 49 E8ercises 44 Chi((er P(ant Part 1 4* So(ution; Chi((er P(ant Part 1 45 Chi((er P(ant Part 6 *9 Chi((er P(ant Part 3 *4 Chi((er P(ant Part 9 ** !,o Stage Co pressor *Naphtha Assay Part 1 *0

SIMULATION OVERVIEW SECTION

'hat is Si u(ation)
Simulation software has had an enormous impact on the petroleum, petrochemical, and chemical process industries over the past several decades. Process simulation is almost universally used to guide the design of new processes, evaluates alternate plant configurations, troubleshoots and debottlenecks plant process, etc. Process simulation programs perform rigorous mass and energy balances for a wide range of chemical processes. Other process engineering tools have been developed for heat transfer simulation, plant gross error detection, piping network simulation, safety system modeling, etc. Dynamic simulation software has also been developed to model plant control systems for detailed engineering studies and operator training. Simulations are based on rigorous first-principle models and the actual plant controls can be used to troubleshoot process and control problems that occur in the actual plant and perform what-if and debottlenecking studies. High fidelity plant simulators are used to train operators in a non-destructive environment. On-line optimi ation has been practiced in the hydrocarbon processing industry for over !" years. On-line optimi ation answers the #uestion of how should a given unit, or groups of units, can be operated to ma$imi e economic given constraints of the operating and economic environment. Optimi ations are typically based on a mathematical model ranging from a unit to a complete manufacturing comple$ based on observed plant performance to rigorous first principles of heat, mass and momentum balances. %ost recent implementations of on-line optimi ation utili e first principles models to take advantage of their superior accuracy, rigor, range, and maintainability.

O+er+ie, of PRO/II
P&O'(( is the flagship offering in SimSci-)sscor*s Process )ngineering Suite +P)S,. -his steady-state simulator performs rigorous mass and energy balances for a wide range of processes. .rom oil and gas separation to reactive distillation, P&O'(( combines the data resources of a large chemical component library and e$tensive thermodynamic property prediction methods with the most advanced and fle$ible unit operations techni#ues. Process engineers benefit from computational facilities to perform all mass and energy balance calculations needed to model most steady-state processes within the chemical, petroleum, natural gas, solids processing, and polymer industries. P&O'(( runs in an interactive /indows0-based 12( environment.

Si u(ation Made Easy

-his manual has been developed to help university students learn how to set up simulations, run them, and analy e the results. /hen setting up a simulation, you can supply data in a number of ways. -he color codes in P&O'(( alert you when data is re#uired, marking the pathway towards a completed simulation. /hen using P&O'(( to develop a simulation, we recommend following these steps3

1#< .ui(d the P/D

Draw the process flow diagram +P.D, by selecting the desired unit operation from the P.D palette and dragging-anddropping that unit on to the flowsheet. 4e$t, draw the feed and product streams for each unit by clicking on the streams button on the P.D palette and drawing a stream by clicking at the desired starting point and then clicking at the at desired termination point. Often a product stream from one unit is the feed stream to another unit. )ntering such streams connects the flowsheet together and establishes the transfer of information within the simulation.

6#< Chec" the Inputs of Measure

5lmost every #uantity has a unit of measure. (nitially the global default for units of measure set is )nglish. 6ou can change this set for this simulation only, or change the global default for all simulations. -he 2O% may also locally override individual dimensional units in data entry windows.

3#< Define the Co ponents

7omponents can be defined by typing their library component names, by selecting from lists of chemicals, or by entering user-defined components, solids with associated particle si e distributions, and polymer components. -here is also an option to generate pseudocomponents from entered petroleum stream assay data.

9#< Se(ect the !her odyna ic Method

Selecting the proper thermodynamic methods is a critically important step in the solution of a simulation problem. .or most problems, a predefined set of thermodynamic methods for calculating 8-values, enthalpies, entropies, and densities may be used. P&O'(( offers numerous categories of method sets. 4ormally one of the thermodynamic systems in the list of %ost 7ommonly 2sed methods is appropriate.

4#< Supp(y Process Strea

Data

.or feed streams, thermal conditions, flowrates, and compositions must be supplied for all e$ternal feed streams to the flowsheet. (t is usually desirable, although not necessary, to provide estimated data for recycle streams to speed convergence of recycle calculations.

*#< Supp(y Process Unit Data

Supply process data for each unit in the flowsheet. 2nit operation identifiers for which data entries are needed are marked with red borders. -o enter information for a unit operation, double-click its icon to open the Unit data entry window.

-#< Run the Si u(ation and %ie, the Resu(ts

9efore trying to e$ecute the simulation, check that there are no red-bordered fields or red linked te$t. (f all the borders are blue, green, or black on the toolbar buttons, unit operation labels, and stream labels then enough information has been supplied to run the flowsheet. -he main portion of the output with all details is contained in the output +:.O2-, file. 6ou can view your results in a variety of ways ranging from plots and tables to pop-up windows with values for each stream and unit to custom reports generated in %icrosoft0 )$cel.

.ui(ding the Process /(o, Diagra

-he first step in any simulation, no matter how small or large, is to draw the process flow diagram. /hile there is a close correspondence between an actual flowsheet and its simulation flowsheet, there are some notable differences. -hese are3

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-ime dependencies 7ombined units

!i e Dependencies
9ecause P&O'(( is a steady state simulator, process e#uipment that control time dependent phenomena are not directly relevant to your simulation. Omit units such as control valves and instrumentation. However, consider the instrument settings when you are deciding on the specifications to make in your flowsheet. -hus3

simplifies to

5ll the control valves, pressure and temperature indicators have been eliminated. 6ou may also eliminate utility systems such as cooling water +as here,, steam and refrigerants from the simulation if you are only interested in the duties they provide.

Setting the Input Units of Measure

5lmost every item of data you will enter in P&O'(( will have 2nits of %easure. .or simplicity, the 2nits of %easure in P&O'(( have been arranged into three standard pre-defined Sets3 )nglish, %etric and S(. 6ou select the set that nearest matches the needs of your simulation and then over-ride the predefined units for individual #uantities. .or e$ample, you may select the %etric Set and override the 7elsius temperature unit with 8elvin. 6ou can set the units of measure on a global, simulation, and'or field level. -he easiest and most efficient way to enter data involves setting the input units of measure for the active single simulation, and then proceed to change the units of measure for a specific field of a unit dialog bo$, if necessary. -o change the default units of measure set for a simulation, click the 2nits of %easure button on the toolbar to open the Default 2nits of %easure dialog bo$.

Figure 1: Default UOM for Problem Data Input Dialog Box

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-o change the default set, click the (nitiali e from 2O% ;ibrary button, select a set, and click O8. %ake any changes to individual units, as desired.

6ou can also use this dialog bo$ to override the -rue vapor pressure temperature basis, the &eid vapor pressure calculation method, and standard vapor conditions. UOM Li=rary 6ou can define and save your own sets by selecting 2nits of %easure ;ists from the Options menu.

$(o=a( Defau(ts
9y default, the standard )nglish set is the global default used to start each simulation. 6ou can change this global default with your own modified set so that every subse#uent simulation starts with that set. Select Simulation Defaults ' 2nits of %easure from the Options menu and select your set from the list.

Figure 2: Default Sets of Units of Measure

Output Units of Measure

4ormally, the output report is in the same units as the input Set. However, you may define a different set of units for the output. Select Simulation Defaults / Units of Measure from the Options menu and select from the lists. (f you do want output in a different set of units it is good practice to get it in the input unit set as well, so that you can check the correctness of your input data. > Select Same as Input for the First Output and your re#uired output set for the Secon Output.

Changing the UOM for a Sing(e /ie(d

/hen entering data in a data entry window, you can still enter individual data items in any appropriate unit.

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Place the cursor in the field for the item whose units you want to change. 7lick the 2O% button on the toolbar to open the !on"ert Units of Measure dialog bo$.

Here you can choose to change the units and retain the value you entered in the field, or to convert the value to the new units.

Figure #: !on"ert Units of Measure Dialog Box

4otice, however, that the ne$t time you open the data entry window the value will have been converted to the set unit of measure.

Defining the Co ponents

Li=rary Co ponents
-he P&O'(( component libraries provide easy automatic access to property data for nearly <""" pure components. /hen running a simulation, you can retrieve the thermophysical properties for a library component from the P&O'(( database simply by using an access name or alias. %any components have more than one alias. .or e$ample, you can retrieve information on met$ane% using any of the following commonly used names3

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7= 7H! %)-H > %)-H54) P&O'(( contains e$tensive component databanks as well as comprehensive methods for component property prediction. (n general when P&O'(( retrieves component data from one of its libraries, it also retrieves the necessary component properties to successfully complete your simulation. (f P&O'(( has incomplete property information for a particular component, you can either ?fill in the gaps@ with established property prediction methods that are based on structural data or input your own component property data. > 7lick the 7omponent Selection button on the toolbar or select Input/!omponent Selection from the menu bar and select your components using the !omponent Selection dialog bo$.

Figure &: !omponent Selection Dialog Box

(f you don*t know the e$act name or alias of a desired component, you can click the Select from ;ists... button and search through the available lists.

Figure ': !omponent Selection ( )ist/Searc$ Dialog Box

Data=an"s
-he P&O'(( component library is actually a composite of several established databanks.

!a=(e 1; Pure Co ponent Data=an"s .a Description n"

S(% S7( P&O 7)S S D(P P& O;( bank id -he S(%S7( pure component databank. -he P&O7)SS pure component databank. Provides for upward compatibility with P&O7)SS and versions of P&O'(( prior to v. A."=. -he 5(7h) D(PP& databank, available as an optional P&O'(( add-on. -he O;( databank, available as an optional P&O'(( add-on. 6our own databank, created and maintained using the Property ;ibrary %anager.

?y default, %&'(II searches the SI)S*I databank first and the %&'*,SS databank second.

Co ponent Properties
7omponents in a P&O'(( databank have a full range of properties. 7omponent properties fall into si$ categories3 .i$ed properties -emperature-dependent properties 2ser Defined and &efinery (nspection properties Solid properties Polymer properties Structure data -he pure component properties that you need to run a simulation may depend upon the selected thermodynamic method. -he re#uired properties are listed for each method in the -hermodynamic %ethods section of the P*O/II *eference Manual. .ollowing, are a few of the most important data re#uirements3

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/ith the e$ception of components declared to e$ist only as solids, all components must have a molecular weight and a specific gravity +which may be alternatively supplied as an 5P( gravity or standard li#uid density,. > .or calculations with an e#uation of state method +such as Soave-&edlich-8wong or Peng-&obinson,, P&O'(( re#uires the critical temperatures and critical pressures of the components. )ach component also re#uires either an acentric factor or a correlation for the e#uationBs alpha parameter. > 8-value calculations with li#uid activity coefficient methods +such as 4&-; and 24(C257, re#uire pure component vapor pressures. Several of these methods also re#uire other properties such as li#uid molar volumes, solubility parameters, or van der /aals area and volume parameters. > 5ll enthalpy and entropy methods re#uire ideal gas enthalpies for each component, with the e$ception of the (deal and Dohnson-1rayson methods. > -he (deal method for li#uid enthalpy re#uires the enthalpy of the saturated li#uid. 2se of this method for vapor enthalpies re#uires saturated li#uid enthalpies, plus the latent heat of vapori ation for each component. (deal li#uid densities re#uire saturated li#uid densities. 5gain, in most cases, you do not need to worry about such re#uirements because the components retrieved from P&O'((Bs databanks will have sufficient data for any thermodynamic method.

/i8ed Properties
-o display the fi$ed properties of the selected components in your simulation, click the 7omponent Properties button on the toolbar and from the !omponent Properties dialog bo$, click the .i$ed Properties button. Here, you can enter userdefined component properties or replace data for library components. -able < displays the sub-dialog bo$ in which each property is located. (n some dialog bo$es you have to scroll hori ontally to see all the properties.
!a=(e 6; Location of /i8ed Properties Dia(og .o8 / Su=> Property Dia(og .o8 Acentric 8actor 8i@ed %roperties ( *arbon )iscellaneous #umber *ritical %roperties 8i@ed *ompressibility %roperties ( 8actor *ritical )iscellaneous %ressure %roperties 8i@ed %roperties ( *ritical %roperties 8i@ed %roperties ( *ritical %roperties

*ritical Temperature *ritical Aolume Dipole )oment ,nthalpy of *ombustion ,nthalpy of 8usion 3ibbs ,nergy of 8ormation 8ree$ing %oint 5#ormal )elting %oint6 3ross Beating Aalue Beat of 8ormation Beat of Aapori$ation Bydrogen Deficiency #umber =iCuid )olar Aolume =ower Beating Aalue )olecular -eight #ormal ?oiling %oint &ackett %arameter &adius of 3yration Solubility %arameter Specific 3ravity Triple %oint %ressure Triple %oint Temperature van der -aals Area and Aolume 8i@ed %roperties ( *ritical %roperties 8i@ed %roperties ( *ritical %roperties 8i@ed %roperties ( )olecular *onstants 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( Beats of 8ormation 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( Beats of 8ormation 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties 8i@ed %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )olecular *onstants 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )iscellaneous %roperties 8i@ed %roperties ( )olecular *onstants

!e perature Dependent Properties

6ou can enter the temperature-dependent properties given in -able A below in either tabular or e#uation form. )$trapolation of temperature-dependent properties outside the user-defined temperature limits is performed linearly, e$cept for vapor pressure and viscosity, which are e$trapolated as ln+property, versus the reciprocal of the absolute temperature. -hese methods are also used for interpolation and e$trapolation of tabular property data and for e$trapolation of the temperaturedependent property correlations retrieved from P&O'((Bs databanks.

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7lick the 7omponent Properties button on the toolbar and from the 7omponent Properties dialog bo$ open the +emperature Depen ent Properties dialog bo$. 7lick the appropriate button to enter user-defined component properties or to replace data for library components.

!a=(e 3; Location of !e perature Dependent Properties .utto Property n ,nthalpy of Aapori$ation Ideal Aapor ,nthalpy

=iCuid Density =iCuid Thermal *onductivity =iCuid Aiscosity Saturated =iCuid ,nthalpy Solid Density Solid Beat *apacity Solid Aapor %ressure Surface Tension Aapor %ressure Aapor Thermal *onductivity Aapor Aiscosity

User Defined Properties

6ou can enter global data for 2ser-defined Special Properties by pushing the 2ser+defined Special %roperties button on the Component Properties dialog bo$. -hese global data will be used for all thermodynamic systems but may be overridden in each thermodynamic system.

So(id Properties
5ll solid properties, fi$ed and temperature-dependent, are entered in the same dialog bo$es as for 2ser-defined components.

Structure Data
7lick the 2#I8A* Structures button on the Component Properties dialog bo$ to define 24(.57 structures for selected components.

Se(ecting the !her odyna ic Method

Selecting the appropriate thermodynamic method for your flowsheet is a critically important decision. Obviously, if you choose a thermodynamic system that cannot accurately model the phase behavior of the process, the simulation results will be invalid. (nappropriate choice of thermodynamic model is the largest single source of error in process simulation and it is always a good idea to verify your selection of a thermodynamic system by comparing simulation results with actual plant operating data. Since it is not possible to develop a single thermodynamic method to model all chemicals under all conditions, P&O'(( uses several different models. )ach works well in some situations and poorly in others. (t is up to you to select the most appropriate methods for your particular flowsheet. Polar components at high pressure should not be simulated with a thermodynamic method that was designed to model low pressure hydrocarbons. Dust because a computer reports convergence to great precision does not mean you should believe that the answers accurately model your actual process. 2se your e$perience and engineering Eudgment to check that results are reasonable

Properties and Syste s

P&O'(( offers numerous methods for calculating thermodynamic properties. 1enerally you must select methods for calculating these thermodynamic properties3

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)#uilibrium 8-values )nthalpies

)ntropies > Densities. (n P&O'((, thermodynamic methods are arranged into systems. /hen you choose a thermodynamic s,stem, P&OF(S(O4 will provide default methods for each of these thermodynamic properties. 6ou may override these defaults. .or e$ample, if the Soave-&edlich-8wong thermodynamic s,stem is selected, the default li#uid density method is 5P(. 6ou may replace this with another method, for e$ample, ;ee-8esler, should you feel ;ee-8esler will predict the li#uid densities more accurately.

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7lick the -hermodynamic Data button, which is outlined in red to show that some data are re#uired.

(n the +$ermo ,namic Data dialog bo$, click on a !ategor, and choose a Primar, Met$o from the selection shown. -ransfer your choice to the Define S,stems list by clicking the 5dd button.

Figure 1-: +$ermo ,namic Dialog Box.

 -o change a default, click the %odify button and make the desired changes. Figure 11: +$ermo ,namic Data/ Mo ification Dialog Box

Idea( Methods (deal methods calculate the mi$ture properties as weighted sums of the pure component properties. )ach componentBs contribution is proportional to its #uantity in the mi$ture. /hile ideal methods often provide good appro$imations for enthalpies and densities, more sophisticated methods are almost always re#uired for 8-values. $enera(i?ed Corre(ations

1enerali ed correlations are empirical or semi-empirical methods, mostly based on the principle of corresponding states. -hey generally do not contain any adEustable binary parameters and are primarily useful for nonpolar hydrocarbon mi$tures. )$amples of generali ed correlations include the 9raun 8-=" +98-=", and 1rayson-Streed +1S, methods. E@uations of State AEOS< )#uations of state are mathematical e$pressions relating the density, temperature, pressure, and composition of a fluid. .rom an e#uation of state, you can calculate component 8-values as well as the departures of enthalpy and entropy from their ideal gas values. /ell-known e$amples of e#uations of state are the ideal gas law and the Fan der /aals e#uation. %ore modern e#uations of state include the Soave-&edlich-8wong +S&8, and Peng-&obinson +P&, e#uations. -hese e#uations often involve the use of binary interaction parameters +usually denoted by k iE, to account for interactions between different components. -hese parameters may be3

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Obtained from P&O'((Bs databanks or internal estimation techni#ues Supplied by the user .it to e$perimental data.

-he basic S&8 and P& e#uations are useful for systems of nonpolar hydrocarbonsG more sophisticated modifications are available to better represent systems containing polar components and to calculate rigorous vapor-li#uid-li#uid e#uilibrium. Li@uid Acti+ity ALAC!< Methods ;57- methods calculate 8-values by starting with an ideal solution and correcting the result with activity coefficients. -he activity coefficients are calculated from a model for the e$cess 1ibbs energy of the li#uid mi$ture. -he most commonly used methods are 4&-; and 24(C257. 9inary interaction parameters are usually necessary. -hey may be3

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Obtained from P&O'((Bs databanks )stimated using the 24(.57 method Supplied by the user .it to e$perimental data.

Dissolved gases may be modeled with HenryBs ;aw, and a heat of mi$ing option may be used to correct for nonideality in the li#uid enthalpy. (f the necessary parameters are available, ;57- methods can successfully describe a wide variety of nonideal mi$tures +particularly mi$tures of components having similar volatility, including mi$tures e$hibiting two li#uid phases.

!ransport Property Methods

5ll simulations re#uire selection of a thermodynamic method. Some also re#uire transport properties - viscosity, conductivity and so on. -ransport properties, if re#uired, are specified from the same dialog bo$. -he unit operations that need transport properties are3

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column +hydraulics, pipe rigorous heat e$changer dissolver depressuring unit


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output tables

-ransport properties include3 Fiscosity -hermal conductivity Fapor-li#uid surface tension

;i#uid diffusivity. .our calculational methods are available for computing transport properties3 Pure Petroleum -rapp 2ser-defined.

-he Pure option applies simple mi$ing rules to the temperature-dependent pure component values available in the selected databanks to calculate mi$ture transport properties. Saturation values are not pressure corrected. -he Petroleum method uses predictive correlations, including pressure corrections, that apply to bulk hydrocarbon mi$tures. -he +rapp option uses a one fluid conformal model to calculate vapor and li#uid viscosities and thermal conductivities for hydrocarbonsG it uses the Petroleum method to calculate surface tension. -he User/ efine option allows you to provide up to five subroutines to compute transport properties. P&O'(( provides a default method for each transport property when you select a transport method +e$cept User/ efine ,. 6ou can choose to override these methods if necessary. .or e$ample, you may select the 0PI +ec$nical Data Boo1 li#uid viscosity method to replace the default Pure li#uid viscosity method. &efer to the P*O/II 2e,3or Input Manual and the P*O/II 0pplication Briefs Manual for selection of the proper transport property method.

E8terna( /eed Strea s

6ou do not have to worry about resetting e$ternal feed streams. P&O'(( automatically flashes these streams prior to flowsheet e$ecution. )ach stream is flashed using the thermodynamic system associated with the unit it feeds. Other user-supplied streams +such as initial estimates for recycle streams, are also flashed to be consistent with the units they feed.

Supp(ying Process Strea

Data

Streams and unit operations are the building blocks of a flowsheet. .or each unit operation you must define at least one feed stream and at least one product stream. 9y defining the product from one unit operation as the feed to another, you establish the connections between the various units in the flowsheet.

!ypes of Strea s
)ven simple flowsheets can contain several different types of streams.

/eed
E8terna( /eed Strea s )$ternal feed streams originate outside the flowsheet. 6ou must provide their thermal condition +e.g., temperature and pressure,, their composition, and their flowrate. -he components in your feed streams can come from P&O'((Bs component library, from assay data, or from user-defined or petroleum components. Interna( /eed Strea s (nternal feed streams are the product of one unit operation and the feed to another. -heir properties are calculated by P&O'(( and although you can provide data for their attributes these data will be overwritten by P&O'(( as soon as the unit operation has solved.

Product Strea s Product streams e$it the flowsheet. -heir properties are calculated by P&O'(( and you cannot provide any of their attributes.

Recyc(e Strea s &ecycle streams are special internal feed streams that connect downstream units to upstream units. P&O'(( automatically recogni es recycle loops and adEusts its calculations appropriately. 6ou can provide estimates for recycle stream properties to help accelerate the solution but it is not usually necessary and a poor estimate is usually worse than no estimate at all.

Recyc(e Con+ergence P&O'(( accomplishes recycle convergence by solving the flowsheet se#uentially using iterative techni#ues. P&O'((Bs default iterative method is irect substitution. (n this techni#ue, the units are calculated se#uentially many times. .or e$ample, if a recycle loop contains units 5, 9, and 7, then the calculational se#uence would be3 5,9,7, 5,9,7, 5,9,7, ... )ach pass through the loop constitutes an iteration. (n the first iteration, the recycle stream has a flowrate of ero, unless you e$plicitly provide an estimate. 5t all other iterations, the recycle stream has the values that were calculated at the end of the previous iteration. -he recycle loop has converged when the recycle stream changes are sufficientl, small between two iterations. -he magnitude of sufficientl, small is determined by the various recycle convergence tolerance parameters that P&O'(( uses +you are free to provide these values,. 6ou must be aware that iterative methods are usually not guaranteed to converge. Direct substitution, however, is fast and reliable for many problems, although it sometimes needs your help. (f you can provide a good initial guess for a recycle stream, the loop may converge faster and more reliably. 9ecause of the greatly increased number of computations, converging recycle loops can re#uire large amounts of time. .or this reason, P&O'(( provides two methods to accelerate convergence. -hese are the /egstein and 9royden methods. 5s is typical with many iterative techni#ues, they work well for some problems and might not work at all for others. 9oth of these methods seek to accelerate the direct substitution method by providing better estimates of the recycle stream at each iteration. 5cceleration methods can often help with problems which tend to oscillate when using direct substitution alone or with problems which approach convergence asymptotically. Se@uencing 5nother way you can control recycle loop convergence is by specifying the calculation se#uence. P&O'(( provides three se#uencing options3

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-he default method, Minimum +ear Streams, orders the calculations to minimi e the number of tear streams. 6ou can think of a tear stream as a stream whose estimate you +or P&O'((, provide to break a recycle loop. -he 0lternate method se#uences the calculations roughly in the order that the units were entered. -his was the default method in versions earlier than P&O'(( A.A". -he 4xplicitl, Define b, User method allows you to choose the ordering of the calculations.

Strea

Properties

9efore you enter data for a stream, you should have placed the unit operations on your flowsheet and connected them together with feed, product, and recycle streams. 6ou should also have declared the components that will be present in your simulation and specified the thermodynamic methods you want to be used. -o define a stream completely you must specify its3

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-hermal condition 7omposition .lowrate

-o open the Stream Data dialog bo$, double click on the stream, or right click on the stream and select Data 4ntr, from the menu. Figure 12: Stream Data Dialog Box

!her a( Condition
P&O'(( re#uires that you provide the thermal condition for all e$ternal feed streams. 6ou must also supply the stream thermal condition if you choose to enter a recycle estimate. -o define the thermal condition, you must specify two of the following three properties3

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Pressure -emperature Phase

!e perature and/or Pressure .rom the First Specification drop-down list select either +emperature or Pressure. (f you want to supply both, select +emperature here and Pressure as the Secon Specification. )nter values in the fields supplied. Phase Phase data are supplied as the Secon Specification after you have supplied temperature or pressure. /hen defining the phase, you may specify the stream as one of3

> > >

a saturated li#uid at its bubble point a saturated vapor at its e3 point a mi$ed phase stream at a li5ui fraction between "." and =.". 6ou may supply molar, 3eig$t or "olume fraction data. )nter the value in the field provided.

Co position and /(o,rate

P&O'(( re#uires you to specify the composition and flowrate of all e$ternal feeds and estimated recycle streams. 6ou can enter the composition of a stream in one of four ways3

> > > > >

2sing defined components 2sing assay or distillation data 9y referencing to another defined stream 9y defining a stream as containing only solids Select the stream type in the Stream +,pe list. 6ou define the flowrate after choosing the stream type.

Co positiona( Strea 7ompositional streams are made up of pure components3 library, user-defined or petroleum. 6ou must always provide the composition.

7lick the .lowrate and 7omposition button to open the dialog bo$.
Figure 1#: Flo3rate an !omposition Dialog Box

(f you do not provide a rate, P&O'(( adds the individual component flowrates to get the total rate. (f you provide a total stream flowrate, the sum of individual compositions entered should be =." +fractions,, ="" +percentages,, or the flowrate that you supply. (f not, select 6ormali7e and P&O'(( will adEust them for you. (f a component does not e$ist in a particular stream, enter a ero value for that component. 9oth composition and flowrate may be given on a molar, weight, standard li#uid volume or standard gas volume basis. 6ou may mi$ bases. .or e$ample, you may enter the total flowrate on a molar basis and enter the component rates on a weight basis. -o change the basis, click in the relevant field and click the 2O% button on the top of the dialog bo$. Standard Conditions (f you enter data on standard li5ui or standard "apor volumetric bases, P&O'(( will use the density of the phase you specify, regardless of the actual physical state of the stream at the specified thermal condition.

.or li#uid volume, P&O'(( determines the molar flowrate using the li#uid densities of the components at standard conditions +H"I. and = atm.,. (n cases where a component is a vapor at standard conditions, the estimated density value comes from the 1PS5 handbook. (f the 1PS5 value is unavailable, P&O'(( e$trapolates from the density of the saturated li#uid at atmospheric pressure. .or vapor volume, P&O'(( uses the defined standard vapor conditions to determine the molar flowrate. -he actual values of the standard temperature and pressure +and therefore the computed flowrate, depend on the default units of measure that you are using. .or the metric and S( systems, S-P defaults to "I7 and = atm of pressure. .or )nglish units, the S-P default is H"I. and = atm of pressure. 6ou can change the standard vapor conditions for your simulation using the Standard Fapor 7onditions button on the Default Units of Measure for Problem Data Input dialog bo$. 5fter determining the molar flowrate, P&O'(( performs an internal flash to bring the stream from S-P to the thermal condition that you have specified.

Petro(eu

Assay Strea

5ssay streams differ from compositional streams by the way in which their compositions are entered and referenced. /hen you input an assa, stream, instead of e$plicitly stating how much of each species is present, you provide simple e$perimental data. P&O'(( uses that data to characteri e the streamBs composition in terms of ?petroleum components.@ -ypically, a laboratory-scale batch distillation analysis, such as the 5S-% DJH procedure, is performed to characteri e a crude stream.

Assay Data Entry

Select Petroleum 0ssa, in the Stream +,pe list. 7lick the .lowrate and 5ssay button to open the data entry window. P&O'(( re#uires the following information for an assay stream3 > .lowrate

> >

Distillation Data 1ravity Data

/(o,rate )nter a value in the field. -o change the basis, click the 2O% button on the top of the dialog bo$. Figure 1&: Flo3rate an 0ssa, Dialog Box

 7lick the Define')dit 5ssay button to open the 0ssa, Definition dialog bo$. Select a distillation type from the list3

> > > >

-rue 9oiling Point +-9P, 5S-% DJH 5S-% D==H" 5S-% D<JJK

4ote that the DJH and D==H" data are almost always reported on a li#uid volume basis while the D<JJK data are always reported on a weight basis. 6our flowsheet may include different types of assay streams +e.g., one stream on a DJH basis and another on a -9P basis,. (f your distillations data has been collected at a pressure other than atmospheric +KH" mm Hg,, you must supply that pressure. )nter the data in the Percent Distille vs. +emperature table. Figure 1': 0ssa, Definition Dialog Box

$ra+ity Data 6ou must supply at least the average gravity for an assay stream, e$pressed as 5P( gravity, Specific 1ravity or /atson 8factor. (f, in addition, you have a gravity versus percent distilled data curve, you should enter it for greater accuracy. 7lick the 1ravity 7urve button to enter the data. Optiona( Data -he following data are optional3

> > >

;ight )nds 5nalysis %olecular /eight Data Special Properties

Light Ends Ana(ysis Often you can identify and accurately measure the #uantity of a few of the lighter components that are present in the petroleum stream. 6ou can supply their rate and composition in terms of library components. Such precisely measured data naturally improves the accuracy of the characteri ation. (f the light ends are included in the average gravity of the stream, enter them here by clicking the ;ightends button and entering the data. (f the light ends are not included in the average gravity of the stream, enter them as a separate compositional stream and mi$ with the assay stream. Mo(ecu(ar 'eight Data (f possible, you should provide measured molecular weight data because the molecular weight correlations are traditionally the least accurate of those used in hydrocarbon characteri ation. 6ou may supply a molecular weight curve without supplying an average value. 7lick the %olecular /eight button to enter data. Refinery Inspection Properties and User>defined Properties Should they be available, you may include &efinery (nspection properties such as cloud point, pour point, sulfur content, and kinematic viscosity in assay form. 7lick the &efinery (nspection Properties button to enter data. 6ou can also include custom defined Special Properties. 7lick the 2ser-defined Special Properties button to enter data.

Reference Strea
5 reference stream is a feed stream whose attributes are defined in terms of another stream +the referenced stream,. -he two streams have the same composition and can have the same rate +molar,, temperature, and'or pressure. Select *eference window to Stream in the Stream +,pe list. 7lick the .lowrate and Stream button to open the data entry

Figure 18: *eference Stream Dialog Box -ypically, when using this option, you transfer the composition of one stream +the source, to another +the target, while overriding the molar rate, temperature, and'or pressure. 6ou may find the reference stream feature most useful when the stream rate, temperature, and'or pressure change, but the composition remains the same.

So(ids Strea
5ll streams may contain solids but there are some streams which contain only solids. -hese are handled differently in P&O'((. Solids-only streams contain only components which have been defined as solid components on the !omponent P$ase Selection dialog bo$, accessed from the !omponent Selection dialog bo$.

>

(n the Stream Data dialog bo$, select Soli s Onl, Stream in the Stream +,pe list. 7lick the Stream Solids Data button to open the dialog bo$.

>

7lick the appropriate )nter Data button to enter molar or weight based solids flowrate and composition. Solid components which do not have molecular weight defined may be entered only on a weight basis. Figure 19: Soli !omponents Dialog Box

(f you have entered particle si e distribution or general attribute data for at least one solid component you may click the Solids 5ttribute )nter Data button to enter particle si e distribution and 1eneral 5ttribute data.

Supp(ying Process Unit Operations Data

P&O'(( is a se#uential modular simulator. )ach unit is calculated separately with the calculations proceeding in a stepwise fashion from one unit to another. P&O'(( uses the unit operations concept to construct the flowsheet. 6ou must define the unit operating conditions, e.g., the outlet temperature of a heat e$changer or the reflu$ ratio for a column. L Co

on /eatures of a(( Unit Operations

5ll unit operations have some common features3

>

2nit identifier and a description. -he unit identifier identifies the unit within the P&O'(( calculations and is used in se#uencing and specifications. P&O'(( supplies identifiers for you automatically. > %ultiple .eeds > -hermodynamic Options > Product Phases

Mu(tip(e /eeds
6ou can supply any number of feeds to a unit. )$ceptions to this rule are highlighted when the unit operation is described. /hen you do not provide a unitBs pressure, P&O'(( sets it to the lowest feed pressure and P&O'(( mi$es all feeds adiabatically at this pressure.

!her o Options
(f you have defined more than one thermodynamic system for your simulation, you can specify which of the defined thermodynamic systems is to be used for the calculations of a specific unit operation. Select the thermodynamic system from the list of available choices within the unit operation. -he default system used for the thermodynamic calculations within individual unit operations is that selected as Default System in the +$ermo ,namic Data dialog bo$. (f the default system is changed, unit operations that have the default choice selected for their thermodynamic method calculations will automatically use the new default system .or unit operations that have an alternative thermodynamic system selected, changing the default system in the -hermodynamic Data dialog bo$ will not change the thermodynamic method used within that unit operation.

Product Phases
%ost unit operations allow you to split the product into one or more streams. 6ou can assign the following phases to product streams3

> > > > > > >

Fapor ;i#uid Solid Decanted /ater Second +heavy, ;i#uid > Fapor M ;i#uid +%i$ture, )$ceptions to this rule are3 Simple heat e$changerNthe rule applies to both sides of a simple HO.

> > > > > >

&igorous heat e$changerNthe rule applies to both sides of a rigorous HO ;41 e$changerNthe rule applies to all cells of an ;41 e$changer .lashNhas to be the .lash with Solids to have a solid phase PumpNonly one product allowed DepressuringNas many products as there are time intervals Solid unitsNone solid and one li#uid +with or without solids,G or one solid and one gas +with or without solids,.

Running the Si u(ation

Interacti+e Run Capa=i(ities
-o run your P&O'(( simulation interactively, you have two options3 the &un button on the toolbar and the buttons on the &un palette. -he easiest way to run your simulation interactively is to click the &un button on the toolbar. -his button will be bordered in red until you have entered the re#uired input data. (f you donBt need to add breakpoints or otherwise step through your simulation, this is your #uickest method. 6ou can stop an ongoing simulation using the Stop button and restart it with the &un button, if desired.

!he Run Pa(ette

.or more control over your interactive simulation, use the buttons on the &un palette. -hrough the &un palette you can perform any of the following tasks3

> > >

7heck the consistency of your input data. Set breakpoints and step through a simulation. Fiew the flowsheet convergence and simulation results.

-o view the &un palette, choose :ie3/Palettes from the menu bar and highlight *un. P&O'(( disables the buttons on this palette until you have supplied all re#uired input data +i.e., there are no red bordered buttons, unit identifiers, or stream identifiers,. -able ! describes the &un palette buttons and their functions.
!a=(e 9; Run Pa(ette .uttons .utto /unction n
Status 7heck Data &un )nables you to view global status messages for the current simulation. 7hecks the input data for inconsistencies. )$ecutes the simulation, either from the beginning or from a breakpoint. 9efore e$ecution, the input data is checked for inconsistencies. )nables you to step through the e$ecution of the simulation by stopping at each unit operation in the calculation se#uence. Stops the simulation during e$ecution. P&O'(( completes its current calculation before stopping. )nables you to select the units you want to assign as breakpoints. /hen the simulation is e$ecuted, it stops at these breakpoints. )nables you to start the e$ecution from any specified unit. 6ou select a unit by highlighting it and then clicking this button. )nables you to view the calculation history and any error messages that arise. )nables you to view detailed output results of a highlighted unit operation or stream in the flowsheet of a simulation. )nables you to see which units are assigned as breakpoints, by displaying these unit icons in magenta. 7licking the button a second time causes the

Step

Stop Set 9reakp oints 1oto

%essag es Fiew &esults Show 9reakp oints

flowsheet to revert to normal display.

Unit Co(or Coding

5s your simulation progresses, individual unit operations change color +unless you disable the S$o3 *un !olors option from the :ie3 menu,. -able P details the relationship between the unit status and its color.
!a=(e 4; Unit Co(or Coding Co( Significance During or Si u(ation E8ecution
Pale 1ree n &ed 1ree n 9lue %ag enta Dark 9lue 2nit operation has not been calculated. 2nit operation has failed to solve. 2nit operation is in the process of being calculated. 2nit operation has been solved. 2nit operation is at a breakpoint. 2nit operation was solved in a previous run.

TECHNICAL REFERENCE SECTION

Using Specification and Define /eatures

-he Specification and Define features of P&O'(( allow you to control your simulation to meet your modeling re#uirements. 2sing Specification and Define you enter target values for flowsheet parameters. P&O'(( meets these targets either directly or by adEusting the values of other parameters. Specification 2sing Specification you set a target value of a calculated unit operating condition or stream property. P&O'(( meets it by varying other parameters either within the unit operation or elsewhere in the flowsheet. 6ou can e$press Specifications either as actual values or as functions of other parameters. .or e$ample, you can Specify a product stream flowrate as =""" and a flash drum temperature as its feed temperature plus =" degrees. Define 2sing Define you link the value of a variable to that of an upstream variable that has already been calculated. .or e$ample, you can Define a .;5SH D&2% pressure as e#ual to the pressure of an upstream valve minus ".= bars.

Specification
6ou can make specifications on parameters within a unit operation or parameters of product streams from the unit operation.. -he number of specifications you can make in a unit operation depends on the number of degrees of freedom that are available to the e#uations that solve the unit. .or e$ample, in a S P;(--)& you can make 4-= specifications where 4 is the number of products. -he 4th product is calculated from the e#uation matri$. A=so(ute Specification Suppose you want to specify that the selected stream should contain ="" kg moles'hr of butane.

> >

(n the Parameter Selection dialog bo$, select Flo3rate then Selecte !omponents, then 6!& as Starting !omponent. &eturn to the Flas$ Drum dialog bo$, click on value and enter ="". 6our absolute stream specification has been set3

Re(ati+e Specification Suppose you want to formulate your specification as a function of another parameter in the flowsheet. Specify that QPR of the butane in the feed is recovered in the selected product stream.

> > >

7lick on S in the linked te$t on the Flas$ Drum dialog bo$ and click on ' parameter. -he linked te$t changes to Select the first parameter as described above. .or the second parameter, select +otal Unit Fee from the !onstant/Stream/Unit list on the Parameter dialog bo$, then select the parameter as before. > &eturn to the Flas$ Drum dialog bo$, click on value and enter ".QP. 6our relative specification is now complete.

Note; (nfeasible specifications are the leading cause of non-convergence of flowsheets. -he specifications you provide
must be realistic. .or e$ample, if a unitBs feed streams contain ="" kg'sec of he$ane, it would be infeasible to specify a product recovery rate of =<" kg'sec of he$ane.

Define
-he Define feature allows you to dynamically link the value of a variable to that of an upstream variable that has already been calculated. /henever the upstream variable changes, perhaps as a result of being in a recycle loop, the value of the Defined variable also changes according to the Definition you have made. 6ou can define almost any input parameter. 6ou know if a parameter is Definable by the state of the Define button on the toolbar. 7lick in the field you want to define. (f the Define button is enabled you can define the parameter.

/(ash Dru
/(ash Ca(cu(ations
/hen you perform design calculations or troubleshoot a process, you may need to know a mi$tureBs phase behavior at certain process conditions, or you may need to know what conditions are necessary to recover a certain amount of a component from a mi$ture. 2sually you must rely on a process simulator to get this type of information.

/(ash Unit Operation

.igure =J shows a general schematic of the P&O'(( .;5SH unit for a vapor-li#uid system. P&O'(( allows up to three products for this unit and an unlimited number of feeds.

4ote that .E denotes the feed streams, F denotes the vapor product, ; denotes the li#uid product, / denotes either the decanted water or the second li#uid product, and Ei, yi, $=i, and $<i denote the component mole fractions for the respective streams. C denotes the duty added or removed from the flash unit operation.

Defining the /(ash Ca(cu(ation

.rom the set of e#uations given above, you can see that )#. +A, sets the phase e#uilibrium behavior for the system. (n )#. +A, the phase e#uilibrium ratios or 8 iBs +also referred to as 8-values, are typically functions of temperature, pressure, and composition, making the problem fairly comple$. 6our selection of a thermodynamic system for the process will greatly affect the solution. 5s previously discussed, there are 4MA variables to be specified for each calculation. -he feed stream composition and rate comprise 4M= of these variables. -his leaves two degrees of freedom to be set in the flash algorithm. P&O'(( re#uires you to specify either the flash temperature or pressure. (n addition, you must provide one of the following parameters3

> > > > > > >

.lash temperature .lash pressure or pressure drop Duty re#uired Product phase +saturated li#uid, saturated vapor, or li#uid fraction, Product stream rate Product stream composition Product stream property +e.g., -FP or specific gravity,.

-he first three parameters represent process operating conditions that you can physically control. -he remainder are design or performance obEectives that you want to achieve.

%a(+e7 Mi8er7 and Sp(itter Unit Operations

-he F5;F), %(O)&, and SP;(--)& units also perform phase e#uilibrium calculations. -hey are each e#uivalent to an adiabatic flash with ero enthalpy change +dutyS",. -he temperature is always computed rather than specified, and P&O'(( allows an unlimited number of feeds to these units. 6ou can set the pressure or pressure dropG otherwise P&O'(( assumes a pressure drop of ero and uses the lowest feed pressure for the product streams. .igures Q-== depict the schematics for these unit operations.

-he F5;F) unit can have up to three products. Designation and handling of the products for the F5;F) unit is as fle$ible as for the .;5SH unit. %(O)& units may only have one productG however, P&O'(( always determines the product phase, regardless of which phase +F, ;, /, or %, you designate.

87, $7i

8o, $oi

8n, $ni

Figure 2-: Mixer Unit Operation

87, $7i

8n, $ni

Figure 21: Splitter Unit Operation

8o7, $o7i 8o , $o i z

om omi

,$

-he SP;(--)& unit combines any number of feed streams and splits the combined feed into products of identical composition and thermal condition. -he same phase designation must be used for all products +i.e., li#uid, vapor, etc.,. (f you select an incorrect phase designation, P&O'(( will reset it to the correct phase, as with the other e#uilibrium calculation units. (n addition, you must define the stream rates using generali ed stream specifications for all but one of the desired products. -he splitter unit allows only rate dependent stream specifications. .or e$ample, the rate of a component or group of components in a product is a rate dependent specification. -he recovery of a fraction of the total feed to the splitter is also a rate dependent specification.

Co pressors
-he !ompressor simulates a single stage isentropic compression. Outlet conditions and work re#uirements may be determined using either an adiabatic or polytropic efficiency. Optional tabular input may be used to determine performance from supplied curves for outlet pressure or pressure ratio, head, work, and'or efficiency. 5n optional aftercooler calculation may be included. 9oth F;) and F;;) calculations are supported. %ultistage compressors may be modeled by linking single

stage compressor units. Figure &: !ompressor Unit Operation

/eeds and Products

5 compressor operation may have multiple feed streams, in which case the inlet pressure is assumed to be the lowest feed stream pressure. 7ompressors may have one or more product streams. -he product phase condition for units with one product stream is automatically set by P&O'((. .or compressors with two or more product streams, the product phases must be specified in the Pro uct P$ases window which is accessed by clicking Product PhasesT on the !ompressor main data entry windo3. 4ote that for compressors with aftercoolers, the products correspond to outlet conditions from the aftercooler. Product phases allowable include3 vapor, li#uid, decanted water, heavy li#uid, and mi$ed phase +vapor plus li#uid,. %i$ed phase is mutually e$clusive with vapor and li#uid products and is not allowed when four product streams are specified.

Specifications
-he pressure, work, or head specification is selected from the drop-down list bo$ in the 7ompressor main data entry window. 5t lease one specification must be supplied for every compressor. (n addition, the efficiency or outlet temperature can also be specified.

&eat E8changers
-he Simple ;eat 4xc$anger may be used to heat or cool a single process stream, e$change heat between two process streams, or e$change heat between a process stream and a utility stream. &igorous calculations may be performed for F;;) systems. (t is also possible to attach an e$changer to any tray of a distillation column and e$change heat between a process stream and a column internal stream, either li#uid or vapor.

Figure ': +$e ;eat 4xc$anger Unit Operation

/eeds and Products

.or reference, streams and products are grouped according to the side of the e$changer as ?hot@ or ?cold@, where the feed stream+s, on the hot side are cooled and the feed stream+s, on the cold side are heated. %ultiple process feed streams are permitted, with the lowest stream pressure used as the inlet pressure. -he product from each side of an e$changer may be phase separated as desired into multiple product streams, where products may be li#uid, vapor, mi$ed phase, and decanted water +hydrocarbon systems only,. -he ?water@ product stream may also be used to represent a second li#uid phase for systems in which rigorous modeling of F;;) thermodynamics is considered. .eed and product streams are accessed via the ;eat 4xc$anger Process Streams window which is opened by clicking Process StreamT on the ;eat 4xc$anger main data entry window. -he product phase condition for units with one product stream is automatically set by P&O'((. .or simple heat e$changers with two or more product streams from a given side, the product phases must be specified in the Pro uct P$ases window accessible by clicking Product PhasesT on the ;eat 4xc$anger Process Streams windo3. Product phases allowable include3 vapor, li#uid, decanted water, heavy li#uid, and mi$ed phase +vapor plus li#uid,. %i$ed phase is mutually e$clusive with vapor and li#uid products and is not allowed when four product streams are specified.

Uti(ity Strea s
.or simple heat e$changers with one process side, a hot or cold utility stream may be defined. -he re#uired utility rate for the specified heat transfer is always computed. 2tility streams may be specified by clicking 2tility StreamT on the ;eat 4xc$anger main data entry window to access the appropriate hot or cold utility window.

7old utility streams are supplied in the ;eat 4xc$anger !ol Si e Utilit, windo3. Options are3

> > >

only.

/ater3 -emperature in and out must be supplied. Sensible heat transfer only. 5ir3 -emperature in and out must be supplied. Sensible heat transfer only. > &efrigerant3 5 designated component is vapori ed at its saturation pressure or temperature. ;atent heat transfer Hot utility streams are supplied in the ;eat 4xc$anger ;ot Si e Utilit, window. Options are3 Steam3 Steam is condensed at its saturation temperature or pressure. ;atent heat transfer only.

> > >

Heating %edium3 5 designated component is condensed at its saturation temperature or pressure. ;atent heat transfer only.

Pu ps
-he Pump may be used to compute the energy re#uired to increase the pressure of a process stream. -his #uantity of energy is added to the feed enthalpy to determine the outlet temperature. Only the bulk li#uid phase is considered in the calculations.

Figure 8: +$e Pump Unit Operation

/eeds and Products

5 pump operation may have multiple feed streams, in which case the inlet pressure is assumed to be the lowest feed stream pressure. 5 single li#uid product stream is allowed from a pump.

Specifications
-he Pressure Specification for a pump is selected with the appropriate radio button on the Pump main data entry window as3

> > >

Outlet Pressure Pressure &ise +DP, Pressure ratio based on the lowest feed stream pressure.

Pu p Efficiency
5 pumping efficiency in percent may be supplied in the data entry field provided on the Pump main data entry windo3. -his value is used for the work and outlet temperature calculations. (f not supplied, a default value of ="" percent is used.

!her odyna ic Syste

-he thermodynamic system of methods to be used for pump calculations may be selected by choosing a method from the +$ermo ,namic S,stem drop-down list bo$ on the Pump main data entry window.

$enerating Output
P&O'(( helps you generate accurate, professional reports. -he standard output report format gives you comprehensive information on all unit operations and stream properties. Or, you can enhance your own reports by including plots, tables, and flowsheet diagrams from P&O'((. 6ou have a wide variety of options at your fingertips for tailoring your simulation results to meet your specific needs including3 customi ing the output report format, e$porting data to spreadsheet programs, creating plots and tables, and annotating your flowsheet.

Interacti+e Output
6ou can interactively view summary results for units and streams. .or individual units, right click on the unit and select :ie3 *esults from the menu. .or individual streams, right click on the unit and select :ie3 *esults from the menu. 6ou can present stream data on the Process .low Diagram in the form of stream labels. 5 Stream Property -able is also very effective. 9y default, the stream label shows the stream identifier. 6ou can present more information on the stream label. &ight-click on a stream and select Displa, from the menu. (n the Stream St,le dialog bo$, set desired style. Figure 22: Stream St,le Dialog Box

(f you make the selections shown above, you get this label display3

Strea

Property !a=(es

P&O'((Bs S-&)5% P&OP)&-6 -59;) feature displays and prints data for flowsheet streams. -o create a S-&)5% P&OP)&-6 -59;)3

> > > >

7hoose Options/Stream Propert, +able from the menu bar, or click the S-&)5% P&OP)&-6 -59;) button on the P.D palette. 5 green outline appears attached to the cursor. 5nchor the table to the P.D by clicking the left mouse button at the desired location. Double-click on the table to open the Stream Propert, +able dialog bo$.

Select a table type from the Propert, )ist to be Use list. 7hange the tableBs appearance using entries in the +able 0ppearance bo$. Select the streams you want displayed.

Figure 2#: Stream Propert, +able Dialog Box

-he simplest property table is the S$ort Propert, )ist which shows the stream attributes below.

Note; (f you want to define your own table, select Stream Propert, )ists on the Options menu. /hen you have
defined your table, return to the Stream Propert, +able dialog bo$. 6our table will appear in the Propert, )ist to be Use list.

E8porting Data
6ou can save a S-&)5% P&OP)&-6 -59;) to a file by highlighting the table and choosing File/4xport... from the menu bar. Select Stream Propert, +able as the data to e$port. -he table can be saved as either tabdelimited te$t or commadelimited te$t. Once youBve saved your S-&)5% P&OP)&-6 -59;) as a te$t file, you can import it into %icrosoft )$cel +or any other spreadsheet program, and then use its data processing capabilities to manipulate and process your data. 6ou can save the flowsheet diagram to the 7lipboard using the 4xport... option from the File menu on the main menu bar. 6ou can then import the flowsheet diagram into other /indows applications using the 7lipboard. 6ou can print the complete flowsheet diagram directly to the printer by selecting .ile'Print from the menu bar. Select Print Setup from the File menu to set the default printer and to choose the print options.

Output Report
6ou can e$amine most of your simulation results through the output report +.O2- file,. P&O'(( contains a wide variety of report options for customi ing your output format. -o set these options, select *eport Format from the Output menu. .rom the sub-menu select3

> > > >

Units of Measure to customi e output units of measure and elect to have two outputs3 one in input units and the other in output units. Miscellaneous Data to customi e report si e, input reprint, overall mass balance and various other options. Stream Properties to customi e stream output bases, -9P reports and other stream-oriented items. Unit Operations to customi e individual unit operation output formats.

Units of Measure On the Default Units of Measure for Problem Output *eport dialog bo$, you can choose the units to be used for your output report. 9y default, the output units of measure set is identical to the input set. (f you choose to use a different set for the output, you can use either a library set or the input set as a basis and you can modify the units used for individual properties as desired. 6ou can also choose to print out two output reports, one in input measurements and a second in the units of your choice. 5 single output file will contain both reports. Misce((aneous Data (n the Miscellaneous *eport Options dialog bo$, you can choose, amongst other things, which portions of the input data you would like reported and whether to include the flowsheet mass balance in your output report. Figure 2&: Miscellaneous *eport Options Dialog Box

Strea

Properties

6ou can choose the way in which your stream data are reported by selecting Stream Properties from the *eport Format menu.

Figure 2': Stream Propert, *eport Options Dialog Box

Unit Operations

You can set print options for individual FLASH DRUMS, COLUMNS, and R AC!ORS "#

selectin$ Unit Operations fro% t&e Report Format %enu.

Figure 28: Print Options Dialog Box Highlight the unit of interest, and click the Print Options button. -he Print Options dialog bo$ for the highlighted unit appears and you can choose which items you want included in your output report. .or .;5SH D&2%S, you can choose whether or not to print !omponent 2/"alues and for &)57-O&S, you can toggle the option of printing the calculation path for the enthalpy balance. .igure PA shows the print options for 7O;2%4S.

Figure 29: !olumn Print Options Dialog Box

5lternatively, you can double-click on the individual unit operation on the P.D and click the Print Options button to get the Print Options dialog bo$.

$enerating a Report
-o generate an output report for your simulation, click the 1enerate &eport button on the toolbar or select :ie3/<enerate *eport from the menu bar. -he default editor appears displaying the contents of your output report. P&O'(( appends the .O2- e$tension to your file name and saves the output file in the same directory that you saved your simulation files. -he default directory is 73US(%S7(UP&O((V/U2S)&. Once you have created your output report, you can view it at any time by selecting Output/:ie3 *eport from the menu bar. 6our default te$t editor displays the output report.

P(ots
6ou can generate and display a variety of graphical plots for your output data. P&O'(( plots output results for3

> > > > > > > >

7O;2%4 7O;2%4

internal flowrates, temperature, and composition separation factor, used for the analysis of column feed point and tray performance one analysis

H)5- )O7H541)& PH5S) )4F);OP)S

H)5-(41'7OO;(41 72&F)S

7ase Study results Physical Properties .eed stream assay curves

P(ot Dri+ers
P&O'(( can display plots using the S(%S7( driver or the following third party packages, such as %icrosoft )$cel and 142P;O- +%icrosoft /indows version,. /ith %icrosoft )$cel, you can change plot colors, a$is titles and other attributes to create a presentation #uality graph. %icrosoft )$cel charts can be easily imported into %icrosoft /ord documents and PowerPoint presentations using the Insert Ob=ect option. 142P;O- is a command-driven interactive plotting program. 6ou can use it to plot both two and three dimensional plots in many different formats.

-o change your plot driver, choose Output/Plot Setup from the menu bar.

$enerating P(ots
-o generate plots in P&O'((3

> > > > >

Select <enerate Plot from the Output menu. Select a unit and an 0"ailable Plot, and click the Plot button. 6ou can3 7opy your plot to the 7lipboard. )$port the plot data to a file as either tab-delimited te$t or comma-delimited te$t. Print your plot.

> >

Save your plot for future reference. Open previously saved plots.

E8porting P(ots to E8ce(

6ou can e$port data to %icrosoft )$cel. Select +ools/Sprea s$eet from the menu bar. 6ou can e$port3

> > > >

plots column reports stream properties component rates

Open an e$isting table or plot and select File/4xport from the graph window to save the data.

On(ine &e(p
P&O'(( incorporates an online ;elp system, a comprehensive reference tool that #uickly accesses information. Online answers are instantly available while you work. (n the ;elp system, commands, features, and data fields are e$plained in easy steps. 6ou can access the electronic !ontents for the ;elp system by selecting ;elp/!ontents from the P&O'(( menu bar. 7onte$t-sensitive help is accessed using the W.=X key or the >$at?s +$is@ button by placing the cursor in the area in #uestion. /hen you have a Cuestion3

> > > > > >

.irst, try using the documentation available on your own computer. -he guides and manuals mentioned here were installed as part of a normal installation of P&O'((. 2se the on-line help system. P&O'(( provides conte$t-specific help in all the data entry windows. (n the P.D %ain /indow, you can enter YHelp %odeY by selecting the /hat is command in the Help menu, or by clicking the /hat is button on the -oolbar. .ollow the sample problems given in the P&O'(( -utorial 1uide. &ead the -roubleshooting section of the P&O'(( (nstallation 1uide. (t contains information on common problem areas and error messages. 4e$t, use the available internet resources. -here is a wealth of information provided by Simsci-)sscor. Fisit the Simsci-)sscor web site and e$plore the product knowledge base. 5nswers to many technical #uestions are available there.

'or"ing ,ith :ey,ord Input /i(es

8eyword (nput files +.(4P, are free format 5S7(( te$t tiles that define a P&O'(( simulation using specific commands known as keywords. 6ou can import, e$port, and run keyword files within the P&OF(S(O4. 8eyword files play many important roles in P&O'((3

> > > >

-hey provide an alternate interface with the P&O'(( calculational module. -hey allow you to maintain compatibility with simulations that were run with earlier versions of P&O'((. -hey provide a compact means of storing simulation input. (f you have several similar flowsheets to run, you can create the first simulation within the 12( and then modify its keyword file and run the rest using File/*un Batc$. 6ou can import e$isting keyword files in the 12( using the ImportA option from the File menu. -his produces a .P&Z file within P&OF(S(O4 if all the features are supported. -o generate a keyword file from your e$isting simulation file, choose the 4xportA option from the File menu and select Simulation Data to 2e,3or File. )nter the path and file name and click O8. 9y default, keyword files have the e$tension .(4P. 8eyword files are easy to read and understand, and data care entered in the following order3 1)4)&5; D5-5 7O%PO4)4- D5-5 -H)&%OD645%(7 D5-5 S-&)5% D5-5 &)57-(O4 D5-5 P&O7)D2&) D5-5 24(- OP)&5-(O4S D5-5 75S) S-2D6 D5-5 6ou can run keyword files using the &un 9atch option from the .ile menu.

Exercises

Chiller Plant Part 1

-hrough guided practice, you will build a simulation of the process shown below. -his is part of a chiller plant typical in natural gas processing. (n subse#uent parts of this e$ample, you will add other sections of the plant to this simulation. <

D+ Enockout Drum

" 0 7"

Figure 1: Sc$ematic of !$iller Plant ( Part 1

-he process and e#uipment data are given in -ables = and <.

!a=(e *; /eed Strea Data Co pone Mo(e

Co ponent

Mo(e

nt
4itrogen 7arbon dio$ide %ethane )thane Propane

B
=." =.H K<.P ==.P H.KP i-9utane n9utane iPentane nPentane 7HP;2S +P)-&O 7omponent,

B
=.<P A." ".PP =.=" ".KP

-otal .lowrate -empera ture Pressure 7HP;2S Propertie s

! O ="K standard vap ftA'day =<"I. <"P psig 49P 5P( 1ravity <= "[ . KA

!a=(e -; E@uip ent Data and Operating Conditions U n Descri Data i ption t
D = 7 = H O = D < P = Scrubbe r 7ompre ssor 7ooler -emperature S JPI. Pressure S <"Apsig Outlet Pressure S H"" psig 5diabatic )fficiency S K<R Hotside3 Process Stream Outlet -emperature S =="I. Pressure Drop S P psi 7oldside3 2tility 5ir (nlet -emperature S J"I. Outlet -emperature S =""I. .lash drum with no change of pressure and no duty. Outlet Pressure S PP" psig )fficiency S HPR

8nocko ut drum Pump

Sol tion! Chiller Plant Part 1

Step 1; Create a Ne, Si u(ation
Select 6e3... from the File menu. 4ote that several buttons on the toolbar, including the &un button have red borders. /hen you have satisfied P&O'((Bs input re#uirements all red borders will disappear.

Step 6; .ui(d the Process /(o, Diagra

(f the P.D palette is not already visible, click the P.D Palette button on the toolbar to bring it up. 7lick on the appropriate unit icons on the P.D palette to draw the P.D. -o select and position a unit, Eust click on its icon. 5 pointer with a bo$ and flash drum attached appears. %ove this to the main window and click again when the unit is in position. (n this manner, select and position the units as shown in the diagram using these P.D buttons3

7lick on the red-bordered Streams button on the P.D palette. 4ote that the pointer now has an S attached to it. 5ll available e$it ports appear on each unit once you select the Streams button. &e#uired e$it ports are red and optional e$it ports are green. Draw the streams on the flowsheet to connect the units. 5fter your first click, only the available feed ports are shown in red or green.

Note; 5lthough not critical in this e$ample, it is good practice to connect the .;5SH D&2% hydrocarbon li#uid product to
the side port and to reserve the bottom port for a decanted water or second li#uid product.

>

Double-click on each stream and unit and change its name to that shown on the diagram above. Do not change any other data in the dialog bo$. 7lick O8 to e$it the dialog bo$. 4ote that spaces are not allowed in unit or stream names. -he completed P.D should now look like .igure < below.

Figure 2: !$iller Plant PFD in P*O/II 5fter you finish building the flowsheet, the labels of all the internal streams are black and the available ports of all the units are green. 5t this point, all the unit labels have red borders and the border of the feed stream label is also red because you must still add data. 4ote that the border of the Streams button is black, indicating that you have entered all necessary data for this function. -o e$it the stream connection mode, right-click, or click on the Streams button so that it turns gray, indicating that the mode is no longer active. 9efore continuing, save the simulation as 7H(;;=.P&Z.

Step 3; Modify the Input Units of Measure

7lick on the green-bordered 2O% button on the toolbar to verify the units of measure used in this simulation. .or this e$ample, you will use either modified S( units or modified )nglish units. 7lick (nitiali e from ;ibraryT and select 46<)IS;/S4+1 or SI/S4+1 from the drop down list.

> >

7heck each item that it matches the input data given in the tables above.

%ake any necessary changes and click O8. 4otice that the border of the 2O% button is now blue indicating that you have modified the data.

Step 9; Define the Co ponents

7lick on the red-bordered 7omponent Selection button on the toolbar.

7lick the Select from =ists button.

>

Select the ;, rocarbon )ig$ten s 7omponent .amily and select components from the list displayed. Select a single component or a group of components +using the shift or control keys, and then click the 5dd 7omponents button to add them to the component list below.

> > > > > >

5dd the components in the order presented in -able H. /hen finished click O8 to return to the !omponent Selection dialog bo$. )nter data for the petroleum component 7HP;2S by clicking the %etroleum button. )nter its name, 49P and gravity data, and click 'E. 4ote that the %etroleum *omponent button and )ist of Selecte !omponents bo$ now have blue borders. 7lick 'E to e$it the dialog bo$.

Figure #: !omponent Selection

Step 4; Se(ect the !her odyna ic Method

> > > >

button.

7lick on the red-bordered -hermodynamic Data button on the toolbar. Select the Most !ommonl, Use 7ategory% and then select Peng/*obinson as the Primar, Met$o .

Double-click on Peng/*obinson, or click the Add +F button to add your method selection to the Define S,stems bo$. -o specify the transport property methods, click the )odifyG button and then the Transport %ropertiesG

> >

7heck the !ompute +ransport Properties option and select Petroleum !orrelations from the +ransport S,stem drop-down list, as shown in .igure !. 7lick 'E in each of the three dialog bo$es to save the entered data.

Figure &: +ransport Properties

Step *; Define the E8terna( /eed Strea

> > > >

Double-click on the feed stream (4;)-V15S. %ake sure that the stream type is !omposition Define . )nter the streamBs thermal condition3 Select +emperature as the first specification and enter value. Select Pressure as the second specification and enter value.

7lick the 8lowrate and *ompositionG button.

Select +otal Flui Flo3rate and enter value. 6ou will need to locally override the flowrate dimensional units. -o do so, with the cursor in the fluid flowrate field, click the 2') button at the top of the dialog bo$ and change the basis to vapor volume and the units to ftA and day. Select the

7hange 2nits button to return to the dialog bo$. > )nter the individual component mole percentages into the component grid. 6ou can move down the list using the +ab key. 5fter entering the composition data, check that the total e#uals ="". > 7lick 'E to e$it each dialog bo$ and return to the P.D.

6ou do not need to enter data for any streams other than the (4;)-V15S +the e$ternal feed stream to the process, because P&O'(( calculates the others for you, based on your process conditions.

Step -; Enter Operating Conditions for Each Unit Operation > Double-click on each unit in turn and enter the re#uired data including the unit identifier.

> )nter data for flash drum D-=. -he First Specification is Pressure and the Secon Specification is +emperature. > )nter data for flash drum D-<. -he First Specification is Pressure Drop and the Secon Specification is Dut,. -he duty of an adiabatic flash is ero. > Note; 5s you return to the P.D after each unit operation, its unit identifier has changed from red +data missing, to black +data satisfied,. > )nter data for heat e$changer HO-=.

> Note; 9y default, the hori ontal stream is the hot side and the vertical stream is the cold side. Here this means that the utility stream is the cold side. 6ou could use this dialog bo$ to change the stream allocations if the reverse were true. > 7lick the Specification button to open the Specifications dialog bo$.

>

Select ;ot Pro uct +emperature from the list and enter value.

Figure ': ;eat 4xc$anger Specifications

> > > > >

&eturn to the ;eat 4xc$anger dialog bo$ by clicking O8. 7lick the cold side 2tility Stream button and enter the appropriate data. 7lose the ;eat 4xc$anger dialog bo$es and return to the P.D. )nter data for Pump P-=. (n the Pump dialog bo$, enter pressure and efficiency data. )nter data for compressor 7-=. )nter values for Outlet Pressure and 0 iabatic 4fficienc,.

Figure 8: !ol Si e Utilit, Stream

/hen you have entered all the data, there should not be any red on the flowsheet. 5ll stream and unit labels should have black borders. (f any of the unit or stream labels has a red border, click on it and check the data. Save the simulation before continuing. Step 5; Run the Si u(ation and %ie, the Resu(ts > &un the simulation by clicking the &un button on the toolbar. )ach unit should turn green and then blue in se#uence indicating that it has solved. > -o view your results, highlight P2%P P-= and click the Fiew &esults button.
3 17 Cal cul ate d ------88. 15 55 . 3#7 . '.# # 1'( 3.( ' ,5.

Pump 'P-1' Feeds Products User Input --------Temperat ure, F Pressure , PSIG Pressure !"se, PSI $or%, &P &ead, FT )**"c"en c+ ,5.

55 .

Figure 9: Pump P/1 *esults

Step 0; Sa+e and C(ose the Si u(ation

6ou will use this simulation as a basis for a later e$ample.

> >

Select Sa"e on the File menu and save as *BI==7.%&H. Select !lose on the File menu.

Chiller Plant Part "

7ontinue to build the chiller plant. Since you already added the 2O%, components, and feed stream data in that part you wonBt need to add these data again. -he diagram shows the process schematic for this part. -he portion of the flowsheet that you entered in Part = is gray, and the new units and streams you will now add are black.

6 10 Compressor D-3 C-1 7 12

D-2Cold 2 4 5 Knockout Drum HX-2 Gas/Gas !c"an#e $nle D-1 t

Gas %cru&&e r er 11 13 'al( e r '-1 4 17 )-1 )ump Figure 1:

Sc$ematic of !$iller Plant ( Part 2 -he new e#uipment data and operating conditions are provided in -able J.

H O <

1as to 1as )$change r

Hotside \P S P psi 7oldside \P S P psi 5pproach -emp +Hot (n 7old Out, S ="I. Hotside Outlet -emp S -=AI. Hotside \P S P psi 7oldside refrigerant saturated li#uid propane at -<<I. 5diabatic Separation

H 7hiller O A D - 7old A Separator F Falve =

Outlet Pressure S <!P psig

Iuestion; -hat is the refrigerant flowrate for Beat ,@changer B1+0J KKKKKKKKKKK

Chiller Plant Part #

7ontinue to build the chiller plant. Suppose that the refrigerant for the chiller HO-A consists of a mi$ture rather than pure propane. 6ou want to determine the flowrate of that mi$ture re#uired to maintain a process stream +hotside, outlet temperature of -=P[.. (nstead of using the H)5- )O7H541)& refrigerant utility in P&O'((, which is designed for use with single components, you now must introduce a refrigerant stream, with the correct composition, and use a 7O4-&O;;)& to determine the refrigerant flowrate. -he diagram shows part of the process schematic. -he portion of the flowsheet that you entered previously is gray, and the new units and streams you will now add are black.

6 10 51CompressorD-3C-1 D-2 Cold 2 4 5 * Knockout

%eparator

Drum HX-2 Gas/GasHX-3 )ropane !c"an#er $nle D-1 C",lle 7 12 t'al(e 3 17 )-1 C-1)ump Figure 1: Sc$ematic of !$iller Plant ( Part # -he e#uipment and refrigerant stream data are shown in -able Q.
!a=(e 0; Refrigerant Strea Data Co p Mo(eB onent
)thane Propane i-9utane Pressure 7onditio n <.P QK ".P ==.P psig 9ubble Point

Iuestions; 76 -hat is the refrigerant flowrate 5Stream 9!6 nowJ 6 -hy is the flowrate different from the flowrate in part 0J

Chiller Plant Part $

7ontinue to build the chiller plant. 5dd a 7O;2%4 and a 7O%P&)SSO&. 2se %(O)& units to combine the plant li#uid streams into one product and the plant vapor streams into another product.

),pel,Gas 1+ Compressor C-1 4

%cru&&e

10 Natura( Li@uidsAN$L<

1: Figure

Sc$ematic of !$iller Plant ( Part &

Cuestions3 =, /hat is the reboiler duty re#uired to meet the li#uid product specification] <, 2sing ?Output'1enerate Plot,@ plot an overview of the columnBs temperatures and flowrates.
Sta=i(i?er Co(u n !>1
5ctual number of trays Overall -ray )fficiency .eed location -op -ray Pressure 7olumn \P 9ottom Product -FP << PPR -ray = <"" psig <.P psi <AP psig

Co pressor C>6
Outlet Pressure H"" psig 5diabatic )fficiency KAR

T%o Sta&e Co'(ressor

5 natural gas stream is compressed before entering a pipeline. -he stream is first compressed to =< bar and then to <H bar. ;i#uid condenses in the compressor aftercoolers and is recycled back to the previous stage. -he li#uid product is removed from the feed flash.

2se the Peng-&obinson -hermodynamic method with the 7OS-5;D correlation for li#uid density. 5ll the data re#uired for this simulation are summari ed in the tables below.

Co ponent /(o,rate A" o(/hr< /(o,rate A(=> o(/hr<

4itrogen 7arbon dio$ide %ethane )thane Propane i-9utane n-9utane iPentane nPentane nHe$ane 7K Plus +model as 47Q, -empera ture Pressure =J" =Q<" =!P<" Q"K" K<H" KK" <J=" QP" =HA" =P!" !"" !<A" A<"" " <""" " =H"" " =K"" H<"" <="" AH"" A!""

A=J"

K""" =""I . K" psia

!"I7 P bar

C>1 Adia=atic Efficiency C>6 Out(et Pressure C>6 Adia=atic Efficiency &C>1 E8it !e peratu re &C>1 Pressure Drop &C>6 E8it !e peratu re &C>6 Pressure Drop

K!R

K!R

<H bar K<R

AJ" psia K<R

H"I7 ".AP bar

=API. P psi

H"I7 ".AP bar

=API. P psi

Answer the following Cuestions;

7 0 :

-hat are the amounts of liCuid and vapor leaving the processJ -hat compressor work is reCuired for each stageJ -hat are the stream temperatures entering the aftercoolersJ -hat are the aftercooler dutiesJ

E8tra Credit;

5nswer the following #uestions3 =, 7an the same information still be obtained with fewer units in the flowsheet] (f so, simulate it and check that the data are available and that the values are the same as in the original calculation. <, 5ssuming that you only want to know the product streams from the process, simulate the process with the minimum number of units re#uired.

Na(htha Assa) Part 1

)nter the assay data for the 4aphtha .eed described below and generate a set of petroleum components. 5lso create a plot of the calculated -9P curve and component cuts. -he light ends make up PR of the total li#uid volume. 2se S&8 thermodynamics with 5P( li#uid density to model the system. -o represent the boiling curve more closely, increase the number of pseudocomponents by using twenty-one =JI. cuts from J"I. to !H"I.. -he process data is given in -able H.

AS!M D5* Data L%B L/

A P =" A" P" K" Q" QP QJ Q" =<P =QP <P" <J" A=" AQ" !=J !A" 5verage 5P( 1ravity .lowrate -emperat ure Pressure

Light Ends COMP MOLB

isobutane butane isopentane pentane -otal ".K" <.=P ".JH A.PJ PR ;i#. volume

P!.< =""" lb'hr =""I. = atm

3enerate the assay processing plot and answer the following Cuestion; 7. -here would you want to generate more pseudocomponentsJ