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Contents iii
2 Modeling Coal Combustion .................................................................................30
Coal Combustion Flowsheet ............................................................................. 31
Starting Aspen Plus ........................................................................................ 31
Opening an Existing Run ................................................................................. 31
If You Completed the Simulation in Chapter 1 and Saved the Simulation..... 31
If Your Saved File Solid1.apw is Not Displayed ......................................... 32
To Access the Examples Folder .............................................................. 32
Saving a Run Under a New Name ..................................................................... 32
Drawing the Graphical Simulation Flowsheet...................................................... 33
Changing the Stream Class.............................................................................. 33
To Change the Global Stream Class ........................................................ 34
Adding Components to the Model ..................................................................... 35
Defining Properties ......................................................................................... 36
Change the Heat of Combustion Method for Coal...................................... 36
Specify Methods for Calculating Ash Properties ........................................ 37
Specify the Heat of Combustion for Coal ................................................. 37
Specifying the Air Stream................................................................................ 38
Specifying Unit Operation Models ..................................................................... 39
Specify the RGibbs Reactor Model .......................................................... 39
Specify the RYield Reactor Model............................................................ 41
Specify the Particle Size Distributions ..................................................... 42
Specify the Component Attributes for Ash ............................................... 43
Specify the Splits for the SSplit Block ..................................................... 44
Defining a Calculator Block .............................................................................. 45
Create the Calculator Block ................................................................... 46
Define the Calculator Variables .............................................................. 46
Specify the Calculations to be Performed................................................. 47
Specify When the Calculator Block Should be Run .................................... 48
Running the Simulation................................................................................... 48
Examining Results .......................................................................................... 49
View the Stream Results ....................................................................... 49
View the Block Results .......................................................................... 50
Exiting Aspen Plus .......................................................................................... 52
iv Contents
To View the Block Results...................................................................... 63
Exiting Aspen Plus .......................................................................................... 64
Contents v
vi Contents
Who Should Read this Guide
This guide is suitable for Aspen Plus users who want to model processes
containing solids. Users should be familiar with the procedures covered in
Aspen Plus Getting Started Building and Running a Process Model before
starting these examples.
Aspen Plus can be used to model many processes involving solids. Some of
the solids processing applications that have been modeled with Aspen Plus
include:
Bayer process.
Cement kiln.
Coal gasification.
Hazardous waste incineration.
Iron ore reduction.
Zinc smelting/roasting.
All of the unit operation models (except Extract) and flowsheeting tools are
available for use in modeling solids processing applications.
This book guides you in introducing solids to a simulation in Aspen Plus. The
four sessions demonstrate the following concepts:
Changing the global stream class.
Defining solid components.
Defining physical property methods for solid components.
Defining component attributes for solid components.
Defining a particle size distribution.
Modifying the default particle size distribution.
Accessing component attributes in a Fortran block.
Modifying component attributes in a block.
Using solids unit operation models.
Getting Started Modeling Processes with Solids assumes that you have an
installed copy of the Aspen Plus software, and that you have done the
sessions in Getting Started Building and Running a Process Model so that you
are familiar with the basics of how to use Aspen Plus.
Aspen Plus Getting Started Building and Tutorials covering basic use of Aspen Plus.
Running a Process Model A prerequisite for the other Getting
Started guides
Aspen Plus Getting Started Using Tutorials covering the use of equation-
Equation Oriented Modeling oriented models in Aspen Plus
Aspen Plus Getting Started Customizing Tutorials covering the development of
Unit Operation Models custom unit operation models in Aspen
Plus
Aspen Plus Getting Started Modeling Tutorials covering the Aspen Plus features
Processes with Electrolytes designed to handle electrolytes
Aspen Engineering Suite Installation Instructions for installing Aspen Plus and
Manual other Aspen Engineering Suite products
Aspen Plus Help Procedures for using Aspen Plus
Technical Support
AspenTech customers with a valid license and software maintenance
agreement can register to access the online AspenTech Support Center at:
http://support.aspentech.com
This Web support site allows you to:
Access current product documentation
Search for tech tips, solutions and frequently asked questions (FAQs)
Search for and download application examples
Search for and download service packs and product updates
Submit and track technical issues
Send suggestions
Report product defects
Review lists of known deficiencies and defects
Registered users can also subscribe to our Technical Support e-Bulletins.
These e-Bulletins are used to alert users to important technical support
information such as:
Technical advisories
Product updates and releases
Customer support is also available by phone, fax, and email. The most up-to-
date contact information is available at the AspenTech Support Center at
http://support.aspentech.com.
Temp = 77 F
Pres = 14.7 PSI
Coal Flow = 10000 lb/hr
Water Content = 25 wt%
DRIER
WET COAL Isobaric
Adiabatic
NITROGEN
Temp = 270 F
Pres = 14.7 PSI DRY COAL
Mass Flow = 50000 lb/hr
Mole Fraction N2 = 0.999 Water Content = 10 wt%
Mole Fraction O2 = 0.001
4 Click OK to close the Options dialog box and apply the changes.
The simulation flowsheet shown in the following figure feeds the WET-
COAL stream and the NITROGEN stream to an RStoic model. In the RStoic
block, a portion of the coal reacts to form water. Because the RStoic
model has a single outlet stream, use a Flash2 model to separate the
dried coal from the moist nitrogen.
5 Place the flowsheet blocks and streams to create the graphical simulation
flowsheet as shown in the figure above. (See Getting Started Building and
Running a Process Model, Chapter 3, if you need to review how to create a
graphical simulation flowsheet.)
7 Click to continue.
The Flowsheet Complete dialog box appears.
Since you chose the Solids with English Units application type when you
started this simulation, Aspen Plus has set the following defaults for
calculating and reporting stream properties:
o The component mass flow rates will be included in the stream report.
o The stream results will be displayed using the SOLIDS stream format.
o Property set ALL-SUBS (properties for the entire stream, all
substreams combined) will be reported for each stream.
6 Click Property Sets to view the selected property sets.
7 Click Close to return to the Stream sheet.
8 Click to continue.
The Components | Specifications | Selection sheet appears.
3 Click to continue.
The Properties | Specifications | Global sheet appears.
Defining Properties
The Properties | Specifications | Global sheet is used to select the
thermodynamic methods used to calculate properties such as K-values,
enthalpy, and density. Property methods in Aspen Plus are categorized into
various process types.
Because the physical property methods for solid components are the same for
all property methods, select a property method based on the conventional
components in the simulation.
The IDEAL property method (Ideal gas and Raoult's Law, as the prompt
indicates) is a good choice for this simulation, since the process involves the
conventional components H2 O , N2 , and O2 , at low pressure.
2 Click to continue.
The Properties | Advanced | NC Props | Property Methods sheet
appears.
Specifying Nonconventional
Solid Physical Property Models
The Properties | Advanced | NC Props | Property Methods sheet is used
to specify the models used to calculate the nonconventional solid properties.
Because nonconventional components are heterogeneous solids that do not
participate in chemical or phase equilibrium, the only physical properties that
are calculated for nonconventional components are enthalpy and density.
In this simulation, use the HCOALGEN and the DCOALIGT models to calculate
the enthalpy and density of coal.
1 In the Model name field for Enthalpy, click and select HCOALGEN.
The component attributes PROXANAL, ULTANAL, and SULFANAL are
automatically included in the Required component attributes for the
selected models field for coal when you select HCOALGEN. Also, four
Option code value fields with values of 1 appear.
Aspen Plus uses component attributes to represent nonconventional
components in terms of a set of identifiable constituents needed to
calculate physical properties. HCOALGEN uses the proximate analysis,
ultimate analysis, and sulfur analysis to calculate the enthalpy of coal.
The Option code value fields define how the HCOALGEN model calculates
the heat of combustion, the standard heat of formation, the heat capacity,
and the enthalpy basis for coal.
7 In the Model name field for Density, click and select DCOALIGT.
The Property Methods sheet is complete:
8 Click to continue.
The Required Properties Input Complete dialog box appears:
Temperature 270 F
Pressure 14.7 psia
Total flow Mass 50000 lb/hr
Composition Mole-Frac
2 Enter the following mole fractions:
Component Value
N2 0.999
O2 0.001
Temperature 77.0 F
Pressure 14.7 psia
COAL component flow 10000 lb/hr
6 Click .
The Streams | WET-COAL | Input | PSD sheet appears.
By default, Aspen Plus uses a particle size distribution of 10 size ranges
covering 20 microns each. The default size ranges are appropriate for this
simulation. On this sheet, enter the weight fraction of coal in each size
range.
7 On the last four Weight Fraction fields, enter the following values:
Interval Weight Fraction
7 0.1
8 0.2
9 0.3
10 0.4
Moisture 25.0
FC 45.1
VM 45.7
Ash 9.2
Ash 9.2
Carbon 67.1
Hydrogen 4.8
Nitrogen 1.1
Chlorine 0.1
Sulfur 1.3
Oxygen 16.4
Pyritic 0.6
Sulfate 0.1
Organic 0.6
Specifying Blocks
The unit operation models RStoic and Flash2 simulate a single piece of plant
equipment for drying coal. Nitrogen provides the heat for coal drying. Both
the RStoic and Flash2 models are isobaric and adiabatic.
1 In the first Flash specifications field, click and select Heat duty in
place of Temperature.
2 In the Heat duty field, enter 0.0 Btu/hr.
3 In the Pressure field, enter 14.7 psia.
4 Click to continue.
6 In the second Operating conditions field, click and select Heat duty.
7 In the Heat duty field, enter 0.0 Btu/hr.
8 Click to continue.
The Blocks | DRY-REAC | Setup | Reactions sheet appears.
This RStoic block models the drying of coal. Although coal drying is not
normally considered a chemical reaction, you are using an RStoic block to
convert a portion of the coal to form water. The following equation is the
chemical reaction for coal drying:
COAL(wet) 0.0555084 H2O
9 Click the Component Attr. tab. Click at the end of the row of tabs, if
necessary, to access it.
The Blocks | DRY-REAC | Setup | Component Attr. sheet appears. On
this sheet, enter the values for component attributes that change in this
RStoic block. If you do not enter an attribute value, the attribute does not
change.
14 Click to continue.
The Required Input Complete dialog box appears.
Although you could run your simulation now, you have not yet created the
Calculator block to control the drying.
15 Click Cancel.
16 Close the Data Browser.
4 In the Reference frame, in the Type field, click and select Compattr-
Var since the variable is a component attribute.
When you are specifying variables, Aspen Plus displays the other fields
necessary to complete the variable definition. In this case, the Stream
field appears.
12 Click to continue.
Note: Ensure that there are 6 spaces at the beginning of each line of the
Fortran statements.
14 Click to continue.
18 Click to continue.
The Required Input Complete dialog box appears.
The connections between the WATER block and the block DRY-REAC and
stream WET-COAL appear as red dashed lines.
Note: The chapter 2 simulation uses this run as the starting point.
Temp = 77 F
Pres = 14.7 PSI
Coal Flow = 10000 lb/hr
Water Content = 25 wt%
DRIER
WET COAL Isobaric
Adiabatic
GASES
DRY COAL
Water Content = 10 wt%
NITROGEN
Temp = 270 F
Pres = 14.7 PSI BURN SEPARATE
PRODUCTS Perfect
Mass Flow = 50000 lb/hr
Mole Fraction N2 = 0.999 separation
Mole Fraction O2 = 0.001 RGIBBS SSPLIT
Temp = 77 F
Pres = 14.7 PSI Isobaric
Mass Flow = 90000 lb/hr Adiabatic
Mole Fraction N2 = 0.79
Mole Fraction O2 = 0.21
SOLIDS
AIR
Note: If you did not create the simulation in Chapter 1, open the backup file
solid1.bkp from the Examples folder.
2 Click .
By default, the Favorites list contains five folders that are provided with
Aspen Plus.
3 Double-click the Examples folder.
4 Select Solid1.bkp and click OK.
Note: If the Connect to Engine dialog box appears, "Connecting to the
Aspen Plus Simulation Engine" on page 89.
The Aspen Plus window appears, displaying the process flowsheet from
Chapter 1.
4 In the Save as type field, click and select Aspen Plus Documents
(*.apw).
5 Click Save to save the simulation and continue.
Aspen Plus creates a new simulation model, Solid2, which is a copy of the
base case simulation, Solid1.
The simulation flowsheet appears different from the process diagram in the
previous figure because the simulation flowsheet uses two unit operation
models to simulate a single piece of equipment. An extra stream (INBURNER)
is defined to connect the two simulation unit operation models. There is no
real stream that corresponds with the simulation stream INBURNER.
3 Click to continue.
Defining Properties
Use the Properties | Advanced | NC Props | Property Methods sheet to
specify the models used to calculate the nonconventional solid properties. In
Simulation 1, Aspen Plus estimates the heat of coal combustion based on its
PROXANAL, ULTANAL, and SULFANAL. In this simulation, enter the heat of
combustion directly.
9 In the Model name field for Enthalpy, click and select HCOALGEN.
The Option code value defaults of 1, 1, 1, and 1 are acceptable for ASH.
10 In the Model name field for Density, click and select DCOALIGT.
19 Click to continue.
The Required Properties Input Complete dialog box appears.
20 Click OK to access the next required input sheet.
Temperature 77.0 F
Pressure 14.7 psia
N2 0.79
O2 0.21
5 Click to continue.
6 Click to continue.
8 Click to continue.
The Yield sheet appears.
For this simulation, the yield distribution you enter on this sheet is not the
true yield distribution. Use a Calculator block to calculate the actual yield
distribution from the component attributes for coal in the feed stream to
the RYield model (stream DRY-COAL).
9 Enter the component yields as follows:
Component Basis Yield
7 0.1
8 0.2
9 0.3
10 0.4
It is not necessary to enter zero for intervals 1 through 6.
Moisture 0
FC 0
VM 0
Ash 100
Ash 100
Carbon 0
Hydrogen 0
Nitrogen 0
Chlorine 0
Sulfur 0
Oxygen 0
Pyritic 0
Sulfate 0
Organic 0
15 Click to continue.
MIXED 1.0
CIPSD 0.0
NCPSD 0.0
13 Click to continue.
Examining Results
View the Stream Results
1 From the toolbar, click .
The Results Summary | Run Status | Summary sheet appears,
indicating that the simulation completed normally.
5 At the top of each column, and click and select INBURNER, AIR,
PRODUCTS, GASES, and SOLIDS.
Results are filled in for each stream as it is specified.
6 Review the results on this sheet. Use the scrollbars to review results that
are off the screen.
Stream PRODUCTS is the outlet of the RGibbs equilibrium reactor that
models the combustion process. Since oxygen appears in stream
PRODUCTS, the combustion process has excess air. An examination of
stream PRODUCTS enables you to determine the most stable products for
each atom in the combustion process:
o SO2 is favored over SO3 and S.
Note: The chapter 3 simulation uses this run as the starting point.
Temp = 77 F
Pres = 14.7 PSI
Coal Flow = 10000 lb/hr
ESP
Water Content = 25 wt%
WET COAL
ESP
DRIER
Isobaric
Adiabatic
NITROGEN
ESP-SOL
Temp = 270 F BAG-FILT
Pres = 14.7 PSI DRY COAL
Mass Flow = 50000 lb/hr Water Content = 10 wt%
Mole Fraction N2 = 0.999 FABFL
Mole Fraction O2 = 0.001 CYC-GAS DP-MAX = 0.5 psi
FILT-SOL
BURN COOLER CYCLONE
HOTPROD COOLPROD
Temp = 77 F
Pres = 14.7 PSI Isobaric Pres = 14.7 psi
Mass Flow = 90000 lb/hr Adiabatic Temp = 400 F
Mole Fraction N2 = 0.79
CYC-SOL
Mole Fraction O2 = 0.21
Note: If you did not create the simulation in Chapter 2, open the backup file
Solid2.bkp in the Examples folder.
2 Click .
By default, the Favorites list contains five folders that are provided with
Aspen Plus.
3 Double-click the Examples folder.
4 Select Solid2.bkp and click OK.
4 In the Save as type field, click and select Aspen Plus Documents
(*.apw).
5 Click Save to save the simulation and continue.
Aspen Plus creates a new simulation model, Solid3, which is a copy of the
base case simulation, Solid2.
1 0 1
2 1 2
3 2 4
4 4 8
5 8 16
6 16 32
1 0.1
2 0.1
3 0.2
4 0.2
5 0.2
6 0.2
10 Click to continue.
10 Click to continue.
The CYCLONE | Input | Specifications sheet appears.
8 Click to continue.
The ESP | Input | Specifications sheet appears.
13 Click to continue.
Examining Results
To View the Stream Results
1 From the Control Panel, click .
The Results Summary | Run Status | Summary sheet appears,
indicating that the simulation completed normally.
In this simulation you will model a simplified polymer washing and drying
process.
You will use:
Component attribute GENANAL to characterize a nonconventional (NC)
component.
The hydrocyclone model (HyCyc).
The counter-current decanter model (CCD).
The cyclone model (Cyclone).
Allow about 30 minutes to do this simulation.
Eff = 0.95
for 100 microns
HCLONE
FEED
WASH-OUT
DRIER CYCLONE
HOT-N2 TO-CYCL
4 Click OK to close the Options dialog box and apply the changes.
5 Click to continue.
The Components | Specifications | Selection sheet appears.
Specifying Components
Use the Components | Specifications | Selection sheet to enter the
components present in the simulation.
The components for this simulation are water, acetone, nitrogen, and
polymer.
1 On the first four Component ID fields, enter H2O, ACETONE, N2, and
POLYMER.
Aspen Plus is able to find WATER, ACETONE and NITROGEN in the
databanks. POLYMER is not found, so the Component name field for
polymer is empty.
By default, Aspen Plus assumes all components have a Type of
Conventional, indicating that they participate in phase equilibrium
calculations. Change the Type for POLYMER to indicate that it is a solid.
Because POLYMER does not have a precise molecular weight, assign
POLYMER the Type Nonconventional.
3 Click to continue.
The Properties | Specifications | Global sheet appears.
Defining Properties
Use the Properties | Specifications | Global sheet to select the
thermodynamic methods used to calculate properties such as K-values,
enthalpy, and density. Property methods in Aspen Plus are arranged
according to process types.
2 Click to continue.
The Properties | Parameters | Binary Interaction | NRTL-1 | Input
sheet appears.
On this sheet, Aspen Plus displays binary interaction parameters for the
NRTL activity coefficient model. Binary parameters are retrieved for all
binary combinations present in the database. If you had data for binary
pairs that are not present in the database, or you wanted to override the
parameters in the database, you could enter your parameters on this
sheet.
Aspen Plus requires you to use this sheet to see what parameters are
available. No further action is required to accept the database values for
the binary interaction parameters. Aspen Plus marks this sheet as
complete as soon as it is displayed.
In this example, parameters are retrieved for the acetone-water pair from
the Aspen Plus VLE-IG databank. Aspen Plus displays the value of the
parameters, and temperature range in which they were regressed. Use
the vertical scrollbar at the bottom right to see all the parameter values.
3 Click to continue.
4 In the Model name field for Enthalpy, click and select ENTHGEN.
As soon as you select ENTHGEN, Aspen Plus assigns the attribute
GENANAL to the component POLYMER.
5 In the Model name field for Density, click and select DNSTYGEN.
16 Click to continue.
The Required Properties Input Complete dialog box appears.
Correct representation of physical properties is an essential component of
process modeling. For many simulations, the only physical property
specification that you must provide is the selection of an option set. The
Required Properties Input Complete dialog box shows that the Aspen
Plus physical property system has many optional capabilities that you can
use to increase the accuracy of physical property calculations.
17 Click OK to move to the next required input.
Temperature 90.0 F
Pressure 16.0 psia
Composition Mass-Flow
ACETONE value 1000 lb/hr
You can access other substreams for stream FEED by changing the
substream name.
Temperature 90.0 F
Pressure 16.0 psia
Composition Mass-Flow
POLYMER value 100 lb/hr
The Streams FEED Input Specifications sheet is now complete.
6 0.2
7 0.3
8 0.3
9 0.2
6 Click to continue.
8 Click to continue.
The Streams | HOT-N2 | Input | Specifications sheet appears.
Stream HOT-N2 is the feed stream used to dry the polymer.
9 Enter the following specifications for the MIXED substream:
Parameter Value
Temperature 350.0 F
Pressure 16.0 psia
Composition Mass-Flow
N2 value 3000 lb/hr
10 Click to continue.
The Streams | WASH-H2O | Input | Specifications sheet appears.
Stream WASH-H2O is the feed stream used to wash the polymer in the
CCD.
11 Enter the following specifications for the MIXED substream:
Parameter Value
Temperature 200.0 F
Pressure 16.0 psia
Composition Mass-Flow
H2O value 400 lb/hr
12 Click to continue.
Number of stages 3
Pressure 15.0 psia
2 For the stage profiles, enter:
Field Value
Stage 1
Mixing efficiency 0.9
Liquid-to-solid mass ratio 2
4 Click to continue.
The Cyclone | Input | Specifications sheet appears.
8 Click to continue.
2 Click to continue.
The HCLONE | Input | Specifications sheet appears.
11 Click to continue.
The Required Input Complete dialog box appears.
Examining Results
To View the Stream Results
1 From the Control Panel, click .
The Results Summary | Run Status | Summary sheet appears,
indicating that the simulation completed normally.
Note: Since this is a scrolling sheet, use the scrollbars to review results that
are off the screen.
4 In the Display field, select Streams.
5 At the top of the blank column of results, click and select ACETONE. In
subsequent columns, select TO-CCD, WASH-H2O, WASH-OUT, and
SLURRY.
Most of the acetone and very little of the polymer are in stream ACETONE.
The hydrocyclone has substantially concentrated the dilute slurry of
polymer in acetone to feed to the CCD.
7 Evaluate the performance of the countercurrent decanter by comparing
streams TO-CCD, WASH-OUT, and SLURRY.
Most of the acetone in TO-CCD is removed by the wash water. Stream
SLURRY contains polymer in a water rich environment. Note that stream
WASH-OUT contains no polymer.
8 After the SLURRY column, click and select the following streams HOT-
N2, TO-CYCL, VENT, and POLYMER.
If either of the following conditions exist, you will be prompted to specify the
host computer for the Aspen Plus simulation engine after you start the Aspen
Plus User Interface:
The simulation engine is not installed on your PC.
The simulation engine is installed on your PC, but the Activator security
device is not connected to your PC.
In these cases, the Connect to Engine dialog box appears.
1 In the Server type field, click and select the type of host computer
for the simulation engine.
If you choose Local PC as the server for the simulation engine, you do not
need to enter any more information into the dialog box.
Note: You should select Local PC and ensure the simulation engine is
installed on your PC. Client-server configurations are no longer supported.
Some features are known not to work in client-server.
If you choose Windows server as the server for the simulation engine,
enter additional information:
2 In the Node name field, enter the node name of the computer on which
the Aspen Plus simulation engine will execute.
3 In the other fields, enter the following information:
User name Your user name for the specified host/server.
Password Your password for the above user name.
Working directory The associated working directory.
4 Click OK to continue.
5 When the network connection is established, the message Connection
Established appears in the message box.
Note: If the Connection Established message does not appear, see your
Aspen Plus system administrator for more information on network protocols
and host computers for the Aspen Plus simulation engine.