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Original Title: MnS Lab Manual 2016

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MnS Lab Manual 2016

Lab manual for practice in modeling and simulation in Aspen HYSYS.

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Institute of Technology

CH702 Modeling and Simulation

LPW

NIRMA UNIVERSITY

INSTITUTE OF TECHNOLOGY

CHEMICAL ENGINEERING DEPARTMENT

LABORATORY MANUAL

B.Tech Chemical

Semester VII

Institute of Technology

Nirma University

Institute of Technology

CH702 Modeling and Simulation

LPW

Sr No

1.

List of Practicals

Defining Streams, Unit Specifications, Degrees of Freedom,

Hypothetical Component Specifications

2.

3.

4.

5.

6.

7.

9.

10.

Basics of MATLAB

11.

Engineering

12.

Institute of Technology

CH702 Modeling and Simulation

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PRACTICAL NO.-1

1

following conditions:

v Fluid Package:

PR EOS

v Flow Rate:

1000 kgmol/hr

v Pressure:

1 atm

v Vapor/Phase Fraction: 1

What is the temperature of this stream? _______________

temperature of 150 C. What is the new pressure of the stream?

Get the answers with various temperatures.

decreases to 0.3 atm what is the corresponding temperature?

and if the pressure is increased to 5 atm, what is the

corresponding temperature?

below:

Temperature:

Pressure:

Flow rate:

F

bar

kg/sec

For multi component check your answers for the following cases.

(a) Specify T, P, Flow rates of all the components.

(b) Specify T, P, Total Flow rate and Mole fractions of all the

components.

(c) Specify T, vapor fraction, Flow rates of all the components.

(d) Specify T, vapor fraction, Total Flow rate and Mole fractions of

all the components.

(e) Specify P, vapor fraction, Flow rates of all the components.

(f) Specify P, vapor fraction, Total Flow rate and Mole fractions of

all the components.

6.

Simulate MIXER, with input streams (two or more) and one output

Institute of Technology

CH702 Modeling and Simulation

LPW

stream.

How is the pressure of the outlet stream calculated?

Observe the properties of each of the streams

Can you find the Bubble point temperature & pressure and

Dew point temperature & pressure for any one of the stream.

Also observe the effect on vapor fraction of the mix outlet by

adjusting the parameter like pressure of the main stream (any

one component)

7.

more) output streams.

Observe that the temperature, pressure and compositions of all

the streams are exactly the same.

8.

stream and two or more output streams.

Can you remove selectively one of the entering components in

the input stream?

Can you observe the difference between flow splitter and

separator?

Find the molar volume of ammonia gas at 56 atm and 450 K using

SRK Equation of State (EoS).

10. Consider the following mixture going into a Water-Gas-Shift reactor

to make hydrogen for the hydrogen economy. CO, 630 kmol/hr,

H2O 1130 kmol/hr, CO2 189 kmol/hr, H2 63 kmol/hr. The gas is at

1 atm and 500 K. Compute the molar volume of this mixture using

SRK EoS.

9

11

properties for following cases and compare your results.

v The boiling point of the component is known to you 399 K.

v Tc=568.83 K Pc=24.86 bar

v Tc=568.83 K Pc=24.86 bar w=0.396

Institute of Technology

CH702 Modeling and Simulation

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PRACTICAL NO.-2

1. Calculate the standard heat of reaction for CO + 2 H 2 CH 3 OH and

compare the result obtained from standard heats of reaction.

2. Calculate

the

adiabatic

CO + 2 H 2 CH 3 OH

under

flame

the

temperature

following

for

the

conditions.

reaction

The

feed

at 25 OC and 1 atm. A conversion of 80% with respect to CO may

assumed. Compare the result with conventional calculation.

3. Calculate

the

adiabatic

CO + 2 H 2 CH 3 OH

under

flame

the

temperature

following

for

the

conditions.

reaction

The

feed

at 25 OC and 1 atm. A conversion of 80% with respect to CO may

assumed. Compare the result with conventional calculation. Observe

the effect of excess reactant on the adiabatic flame temperature.

4. Calculate

the

adiabatic

CO + 2 H 2 CH 3 OH

under

flame

the

temperature

following

for

the

conditions.

reaction

The

feed

1:2:5 enters the reactor at 25

OC

conventional calculation. Observe the effect of the presence of a

diluent on adiabatic flame temperature.

5. Perform Design calculations with any kinetic reactor (PFR/CSTR).

Determine the volume necessary to produce 300 million pounds of

ethylene a year from cracking a feed stream of pure ethane. The

reaction is irreversible and elementary. It is required to obtain 60%

conversion of ethane, operating the reactor isothermally at 1150K

Institute of Technology

CH702 Modeling and Simulation

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C 2 H 6( g ) C 2 H 4 ( g ) + H 2 ( g )

(A + B -> C)

Kcal/gmole.

6

(C4H8O2). Ethanol (C2H5OH) is combined with Acetic Acid

(CH3COOH) to Ethyl Acetate in a reactor. The reaction is:

C2H5OH + CH3COOH

C4H8O2 + H2O

Feed:

Temperature:

70oC

Pressure: 1atm

Water:

8.892 kmol/hr

Ethanol:

186.59 kmol/hr

Acetic Acid: 192.6kmol/hr

Property Package: NRTL

Kinetic Parameters:

Reactions are first order with respect to each reactants in

the reaction (second order overall).

Forward reaction: k = 1.9 x 108, E = 5.95 x 107 J/kmol

Reactions occur in Liquid Phase

Composition basis is Molarity.

Reactor Conditions: Temperature: 70oC, Pressure: 1 atm

Determine the product flow rate assuming the reactor is a

CSTR with a Vol = 0.14m3.

Determine the product flow rate assuming the reactor is a

PLUG flow with Length = 2m and Diameter = 0.3m.

Determine the product flow rate assuming the reactor is a

Conversion type with a 70% conversion of ethanol.

7.

has the fourth highest production rate behind the monomers of

ethylene, vinyl chloride and propylene. Styrene is made from the

dehydrogenation of ethylbenzene:

..1

Model this system using a power law expression. [In HYSYS

Institute of Technology

CH702 Modeling and Simulation

LPW

expression that you will install is given by the following:

Notice that the reaction rate has units and that the concentration

term is partial pressure with units of kPa.

Institute of Technology

CH702 Modeling and Simulation

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PRACTICAL NO.-3

1.

Water at 50

OF

Simulate to find the required pump power and the required pump

pressure rise for this scenario.

2. 25,000 Ib/hr of toluene is pumped from 75 OF and 30 psi to 570 psi.

Simulate to compute the capacity, pump head, the exit temperature

and the horse power for (a) a pump efficiency of 100% and (b) a

pump efficiency of 75%.

3. Simulate to find the heat required to vaporize 45 mole % of a liquid

stream entering an evaporator at 50 OF and 202 psia and containing

propane 250, n-butane 400, n-pentane 350 lbmole/hr. assume that

the evaporator product is at 200 psia.

4. Use a simulator to design a compression system with inter coolers to

compress 600 Ib/hr of a mixture of 95% hydrogen and 5 mol%

methane at 75

OF

maximum exit temperature from stage is 400 OF. Assume gas outlet

temperature from the intercoolers is 120 OF

5. You need to mix a stream of natural gas (consider only C1 here) with

steam before sending them to the natural gas reformer where they

will react to form CO and CO2. You cannot just mix them in any

proportion, however. Though stoichiometry might suggest you could

use nearly a 1:1 ratio, you must avoid a possible side reaction

whereby solid carbon (coke) is formed, choking the reactor. To avoid

this reaction you are told to maintain at least a 3:1 Steam to Carbon

Ratio (i.e. for every carbon atom entering the reactor, there should be

3 molecules of water). Use Set Tab to do so.

Institute of Technology

CH702 Modeling and Simulation

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PRACTICAL NO.-4

1. 1000 lbmol/hr of ethylene stream (S1) at 100 F is mixed with

toluene (S2). The flow rate of toluene stream at 50F is adjusted to

achieve the desired temperature of 85 F at the mixer effluent.

Simulate the unit and find the flow rate of the stream S2.

2. Simulate to determine the flow rate of saturated vapor benzene at

176.2 F to be mixed with 100 lbmole/hr of liquid benzene at 1 atm

to raise its temperature from 25 to 50 F.

3. For the following calculate the flow rates of recycle and products

streams.

Feed Pure Isobutane

100 kmol/hr

Mixer

Product

95 (mol%) isobutene

5 (mol %) isobutene

Recycle

80 (mol %) isobutane

20 (mol %) isobutene

4.

and 14.7 psia is to be heated to 752 F and 73.48 psia. Following

two options are available: (1) The liquid ethyl benzene is sent

through a pump to increase the pressure to the desired value

followed by heating it to the required temperature (2) the liquid ethyl

benzene is first vaporized at constant pressure to an intermediate

temperature and then compressed to the required pressure. Which

of these options do you recommend? Check your answer by

simulating both the options.

Using case study option, see the effect of temperature on the molar

volume of the ammonia in Practical 1 problem 9.

Institute of Technology

CH702 Modeling and Simulation

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PRACTICAL NO.-5

1. A binary mixture consisting of 50 mol% n-pentane and 50 mole % nHexane at 130 F and 73.5 psi is fed into a flash column. The flash

column operates at 120 F and 13.23 psia pressure. Simulate the

unit and report the fraction of vapor along with the compositions of

the liquid and vapor stream. Observe the heat duty in the column.

Try to connect a Heat stream to the column and observe its value.

2. Hot water at 250 C and 1000 psig is used to heat a cold stream of

water in a shell and tube heat exchanger. The inlet temperature and

pressure of the cold stream is 25 C and 130 psig respectively. The

outlet temperatures of the cold and hot streams are 150 C and 190

C, respectively. If the flow rate of the hot stream is 100 kg/h,

determine the flow rate of the cold stream passing through the

exchanger.

3. In the above problem if the flow rate of the cold stream is 100 kg/hr

determine the flow rate of hot stream passing through the exchanger.

What is the amount of heat transfer from the hot stream to the cold

stream?

4. Design a binary distillation column.

Example: Feed consisting of Methanol 36.8 % and 63.2 % water.

Feed Flow rate: 120000lb/hr, Pressure 18 psia, Saturated liquid

Reflux Ratio: 1.3; Desired Separation 98 % methanol in the top

product and 98% water in the bottom product. [Hint: First use short

cut distillation to obtain the required data for distillation design and

then use adjust tab to obtain the required purity]

5. In an Ammonia reactor loop, the feed consisting of NITROGEN 24

lbmol/hr, HYDROGEN 74.3 lbmol/hr ARGON 0.6 lbmol/hr and

Institute of Technology

CH702 Modeling and Simulation

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reactor

(Modeled

as

Equilibrium

reactor

with

zero

degree

The

vapour and liquid product streams from the reactor are mixed and

cooled to -28 F and 2000 psia. The liquid stream from the flash

column is withdrawn as product and the vapour stream is partially

purge ( a purge fraction of 0.04 may be used) and then compressed

to the reactor pressure of 200 atm. Simulate the process and report

the conversion obtained in the reactor along with the product and

recycle flow rates.

Institute of Technology

CH702 Modeling and Simulation

LPW

PRACTICAL NO.-6

1. Simulate the following Block diagram. See the effect of pressure

drop through expansion valve on vapor phase composition. [Use

sensitivity analysis]

reaction of HCl with ethylene over a copper chloride catalyst:

C2H4(g) + HCl(g)

C2H5Cl(g)

diagram is as shown below. Simulate the process. Study various

parameters of recycle tab.

Also carry out the sensitivity analysis for the effect of purge flow

rate on Recycle flow, Product flow, Flow to distillation column and

composition of recycle stream.

Institute of Technology

CH702 Modeling and Simulation

LPW

PRACTICAL NO.-7

Design a Distillation column for the following flow sheet. Simulate

the same using following steps.

1. Use the component splitter first.

2. Use set tab to determine the pressure of condenser and reboiler.

[Assume saturated vapor at top and saturate liquid at bottom.

Also assume the pressure on condenser same as that of feed]

3. Determine the effect of pressure on relative volatility of C3H8

and nC4H10m using a case study. [Use clone object for Feed and

set its vapor fraction to 0]. Relative volatility needs to be defined

using spreadsheet.

4. See the effect of Pressure on Temperature of both distillate and

bottoms.

5. Re define the pressure of condenser using the observation of the

above studies.

6. Use these pressures for defining short cut distillation. Simulate

the short cut distillation and finally using the results of short

cut distillation simulate the given distillation column.

Institute of Technology

CH702 Modeling and Simulation

LPW

PRACTICAL NO.-8

(Case Studies (Solve any one using Aspen.Hysys))

1. Toluene is produced from n-heptane by dehydrogenation over a

Cr2O3 catalyst: CH3 CH2 CH2 CH2 CH2 CH2 CH3

C6H5CH3 +

4H2. The toluene production process is started by heating nheptane from 65 to 800 F in a heater. It is fed to a reactor, which

operates isothermally and converts 15 mol% of the n-heptane to

toluene. Its effluent is cooled to 65 F and fed to a separator (flash).

Assuming that all of the unit operated at atmospheric pressure,

determine the species flow rates in every stream. Inspection of the

calculation of the results of the above example shows that the

cooling duty is comparable to heating duty, suggesting that the

utility load can be reduced by preheating the feed stream with hot

reactor product. Modify the process by adding a heat exchanger.

2. We need to separate a mixture of five paraffins into light and heavy

fraction by using multistage distillation column with 12 ideal trays,

a total reflux condenser, and a reboiler. The feed stream (1000

lbmols/hr) consists of 3% (mole %) ethane, 20% propane, 37%

nbutane, 35% n-pentane, and 5% n-hexane at 2250 F and 250

psia, which enters the column on the seventh tray, counting from

the top. The condenser and reboiler pressures are 248 and 252

psia, respectively. The preliminary design specifications require a

reflux ratio of 6.06 and a vapor overhead product of 226 lbmol/hr.

Subsequently, the design is modified to ensure propane overhead

recovery of 191 lbmol/hr and butane bottom recovery of 365

lbmol/hr.

Note:

Estimated condenser

temperature 100F and reboiler

temperature 240F.

Distillate rate 226 and reflux ratio 6.06

Fluid Package SRK

3. Ethyl chloride will be produced by the gas-phase reaction of HCl

with ethylene over a copper chloride catalyst supported on silica as

C2H4 + HCl C2H5Cl

The feed stream is composed of 50 mol% HCl, 48 mol% C2H4, and

2 mol% N2 at 100 kmol/hr, 250C, and 1 atm. Since the reaction

achieves only 85 mol% conversion, the ethyl chloride product is

separated from the unreacted reagents, and the latter is recycled.

The separation is achieved using a component splitter, where it is

assumed that a perfect separation is achievable. The process is

Institute of Technology

CH702 Modeling and Simulation

LPW

To prevent the accumulation of inerts in the system, 10 kmol/hr is

withdrawn in a purge stream, W. Simulate the process.

Note: Component splitter is used for separating the product

ethylchloride from the reactant and the conditions are 25 C and 1

atm in the splitter.

Property Package: Peng Robinson

Institute of Technology

CH702 Modeling and Simulation

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PRACTICAL NO.-9

1. Enter the following matrix in MATLAB:

a=[1 2 3;4 5 6;7 8 9]; b=[10 11 12;13 14 15;16 17 18]

Carry out the following operations in MATLAB workspace

Array Addition

Array subtraction

Array Multiplication

Matrix Multiplication

Array right division

Array left division

Matrix Right Division

Matrix Left Division

Array Exponentiation

2. x=[1 2 3 4 5 6 7 8 9 10];

Use the linspace command, input command to enter the matrix

3. Use the following functions of MATLAB.

inv, eig, rank, det

[ Use help function_name for more details]

Institute of Technology

CH702 Modeling and Simulation

LPW

PRACTICAL NO.-10

1. Convert the following temperature from degree Celsius in Kelvin

50

70

80

95

100

105

110

120

135

Using K=273.15+C. plot (C,K) .

2. Write a function file to find out the BUBL P of any ideal binary

system.

- Modify the above programme by including global variables

3. Carbon dioxide gas is well represented by the van der Waals

equations of state. Given that T=190 K and P=1 atm, find out the

volume of carbon dioxide gas using any numerical method. The

Van Der Waals equation of state is given by

a

P + 2 (V - b ) = RT .

V

available to you.

Institute of Technology

CH702 Modeling and Simulation

LPW

PRACTICAL NO.-11

Water is flowing into a well-stirred tank at 150 kg/hr and Methanol is

added at 30 kg/hr. The resulting solution is leaving the tank at 120

kg/hr. There are 100 kg of fresh water in the tank in the beginning.

Develop a model listing your assumptions and calculate the outlet

concentration of Methanol at various time interval from t= 1 hr to 10 hr.

Simulate the process using MATLAB and g-PROMS.

Institute of Technology

CH702 Modeling and Simulation

LPW

PRACTICAL NO.-12

1. Suppose that a reaction is going as A B with the reaction rate

dC A

given by,

= -kC A where k is a reaction rate constant. If the

dt

value of is k=0.3 min-1, determine how long will it take for the

conversion to reach 95%, if initial concentration of A is 10 mol/lit.

Solve using MATLAB. Plot CA v/s t.

2. Suppose we want to model the nonisothermal CSTR,

temperature, Tj, as, the input (i.e. manipulated variable). We will

also want to monitor concentration and temperature of the liquid

in the CSTR as our outputs. Given that,

Use MATLAB to solve the above model equation for various Tj values and

plot the Ca and T as a function of time for various Tj.

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