Aspen HYSYS - Your Very First HYSYS Simulation

Chemical Engineering Guy
www.ChemicalEngineeringGuy.com
Change:
• All T of Reactors
• Feed Composition
• No. of Plates in Distl. Col
• T of Heat Ex
• Gas Sep. T
• Compressor P
• Utility Costs
 Makes us easier/faster work
 Multiple and Simultaneous Simulations
 Different Real-Life Scenarios
 Change on raw/feed materials scenario
 Pricing and Costs calculation

 Raw Materials
 Plant Cost
 Utilities
 How it would behave under different conditions

 High/Low Pressure
 Humidity Changes
 Temperature change (cool/warm days/seasons)
 Mainly:
 Petrochemical
 Pharmaceutical
 Fine chemicals
 Other commodities such as:

 Sulfuric acids
 Chlorine/Caustic industry
 Solvents
 Coatings
 Many more…
 Excelent for your curriculum as an engineer
 Perfect for analytical/numerical minds
 Good for debuging and fixing “what if” scenarios
1. Introduction
2. Our Chemical Process!
3. Setting up the Physical Property Environment
4. Simulation Environment I – The Flowsheet
5. Simulation Environment II – Unit Operations
6. Running, Results & Analysis
7. Case Studies (A,B,C,D)
8. Conclusion
 Introductory Knowledge of Processes Modeling
 Setting the adequate Physical Properties
 General Flowsheet Concepts
 Basic Flowsheet “manipulation”
 Common Unit Operations
 Minimum Requirements to set up & run a Simulation
 Analyze several changes in process conditions
 Create an interest in Process Modeling
 Please contact me if required (doubts, questions, comments, suggestions)
 Contact@ChemicalEngineeringGuy.com
 More courses…
 Unit Operations
 Heat Exchange
 Heat Exchanger
 Reaction Kinetics
 Combustion Chamber / Reactor
 Momentum
 Pump
 Turbine / Expander
 Separation Process
 Flash Drum
 Distillation Columns
 A stream of three hydrocarbons are to be treated as follows:
 Methane, Iso-Pentane and Dodecane must be separated.
 Methane is only useful as a fuel, must be separated in a flash drum and sent to stack
 Main separation is achieved in a Flash Drum
 P/T is adjusted to: 15°C, P = 456.6 kPa. Operation is Adiabatic
 Dodecane and isopentane are valuable, so they must be further separated

 P/T conditions are adjusted for the Column
 The distillation column operates with a partial condenser and reboiler
 The current operation states that:
 N = 20 stages, being fed at 10th stage. Reflux ratio is 2.5 approx., with 2.15 – 21.50 Gas-Distillate Ratio
 Dodecane is required at 150 kPa in the following Plant but Iso-Pentane is ready to ship to client.
 The Combustion chamber has the following conditions:
 Approx. 100% conversion
 Q = adiabatic operation
 Air is used for oxidant
 T = 350°c, P = 405 kPa inlet conditions
 dP = 125 kPa approx.
 Turbine is used to decrease Pressure of the stack gas.
 Requirements
 Model the plant using Aspen HYSYS in Steady State
 Verify Material/Energy Balances of the unit operations & processes
 Verify purity and composition of streams
 Verify conditions such as T, P and Flow rates.
 For specific unit operations, verify their relevant results
 Heater  Heat duty
 Combustion Chamber  T-max, Heat released by reaction
 Compressor/Pump  Required Work
 For the Columns  Reboiler & Condenser Duties
 Landing Page
 Min. Requirements:
 Adding Components to the Component List
 Selecting a Physical Property Method (Thermodynamic pack)
 If you want to further explore this environment 

 Aspen HYSYS - Petroleum Assays and Oil Characterization
 Different Types of Components
 Methods (EOS, Activity, Mixed)
 Modeling new/inexistent components
 Modeling Crude Oils & Petroleum Assays
 Blending & Installing Oils
 Add the following to the list:
 Methane, CH4
 Iso-Pentane, iC5
 Dodecane, C12
 Later, we will add:

 CO2, H2O, O2, N2 (air)
 For now, select a EOS Method
 Peng Robinson is excellent for this model.
 The Simulation Environment Overview
 Manipulation of the flowsheet
 Adding Streams (Material / Energy)
 Input of data
 Two raw-material streams:
 Stream Feed:
 100 kmol/h
 T = 30°C, P = 506.6 kPa
 Air (21% O2, 79% N2)

 300 kmol/h
 T = 350°C, 405 kPa
 Adding Unit Operations
 Setting up Unit Operations
 Connectivity
 Running Simulation along…
 Streams:
 Material  inlet: P-Feed
 Material  outlet: Feed
 Energy  outlet: Q-Chiller
 Conditions:
 dP = 50.66 kPa
 T = 15°C
 Tip  Setup up the temperature of the outlet stream
 Streams:
 Material  inlet: Feed
 Material 
 outlet: Gas
 outlet: Liquid
 Energy  N/A
 Conditions:
 T = 15°C
 Streams:
 Material  inlet: Gas
 Material  outlet: Warm-Gas
 Energy  inlet: Q-Heater
 Conditions:
 dP = 50 kPa
 T = 350°C
 Streams:
 Material  inlet: Liquid
 Material  outlet: Col-Inlet
 Conditions:
 P-final= 1 atm
 Tip  Setup up the pressure of the outlet stream
 Add Reactions in the Physical Property Environment
 Use  Equilibrium Reactions (Activity)
 CH4 + 2O2 → CO2 + 2H2O
 C5H12 +8O2 → 5CO2 + 6H2O
 C12H26 + 18.5O2 → 12CO2 + 13H2O
 NOTE  Add to FP
 Streams:
 Material 
 inlet: Air
 inlet: Warm-Gas
 Material 
 outlet: Stack
 Outlet: Reactor-Liq
 Conditions:
 dP = 125 kPa
 Q = 0 (adiabatic)
 Streams:
 Material  inlet: Stack
 Material  outlet: Off-Gas
 Energy  outlet: Mecha-Work
 Conditions:
 Efficiency (adiabatic) = 85.7%
 P-final  1 atm
 Streams:
 Material  inlet: Liquid
 Material 
 outlet: Distillate
 outlet: Bototms
 Energy  Inlet: Q-Reb
 Energy  Outlet: Cond
 Conditions:
 Stages
 N = 20 stages
 Feed = 10th
 Default Reboiler
 dP = 0, Pcond = Pboil = 101 kPa
 No temperature estimates
 Condenser = partial
 Reflux = 2.5, molar
 Gas = 2.15 kmol/h
 Distillate = 21.50 kmol/h
 Page (1/5)
 Page (2/5)
 Page (3/5)
 Page (4/5)
 Page (5/5)
 Streams:
 Material  inlet: Bottoms
 Material  outlet: Decane
 Energy  Pump-Workload
 Conditions:
 P discharge = 150 kPa
 Tip  Setup up the pressure of the outlet stream
 Workbook
 Streams
 Blocks
 Workbook
 Streams
 Blocks
 Let us now change some process conditions
 Verify the input/output of the new changes
 Case Studies
 A) Change Air from 300 kmol/h to 350 kmol/h
 B) Effect of temperature in chiller (15°C  30°C)
 C) Effect of distillate-gas ratio (1:10 to 1:5)
 D) Effect of number of trays (20 to 30)
 A) Change Air from 300 kmol/h to 350 kmol/h
 B) Effect of temperature in chiller (15°C  30°C)
 C) Effect of distillate-gas ratio (1:10 to 1:20)
 D) Effect of number of trays (20 to 30)
1. Introduction
2. Our Chemical Process!
3. Physical Property Environment
4. Simulation Environment I – The Flowsheet
5. Simulation Environment II – Unit Operations
6. Results & Analysis
7. Case Studies
8. Conclusion
 Introductory Knowledge of Processes Modeling
 General Flowsheet Concepts
 Setting the adequate Physical Properties
 Basic Flowsheet “manipulation”
 Minimum Requirements to set up simulation
 Common Unit Operations
 Create an interest in Process Modeling
Change:
• All T of Reactors
• Feed Composition
• No. of Plates in Distl. Col
• T of Heat Ex
• Gas Sep. T
• Compressor P
• Utility Costs
 Typically, you will follow your training with
 Basic Course
 What do you learn there:

 More on Aspen HYSYS
 More on Physical Property Environment
 Flowsheet techniques
 More Unit Operations
 Analysis Tools
 Plenty Workshops
 Process & Industry Case Studies
 Aspen HYSYS – Basic Course!
 1 Month Free Trial then $8.00 USD/month
 Aspen HYSYS – Training Bundle includes:
 Aspen HYSYS – Your First Simulation
 Aspen HYSYS – Basic Course
 Aspen HYSYS - Petroleum Assays and Oil Characterization
 All other new upcoming Aspen Plus courses

Aspen HYSYS - Your Very First HYSYS Simulation

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Chemical Engineering Guy

 Pricing and Costs calculation

 How it would behave under different conditions

 Other commodities such as:

 Perfect for analytical/numerical minds

 Good for debuging and fixing “what if” scenarios

 Dodecane and isopentane are valuable, so they must be further separated

 Turbine is used to decrease Pressure of the stack gas.

 If you want to further explore this environment 

 Later, we will add:

 Air (21% O2, 79% N2)

 Tip  Setup up the temperature of the outlet stream

 Tip  Setup up the temperature of the outlet stream

 Tip  Setup up the temperature of the outlet stream

 Tip  Setup up the pressure of the outlet stream

 What do you learn there:

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