Professional Documents
Culture Documents
Author
P. Johnson
1
Table of Contents
ND
1 INTRO TO HYSYS FOR 2 YEAR .................................................................................................................... 3
1.1 WHY USE HYSYS? (OR SIMULATIONS).............................................................................................................. 4
1.2 GETTING STARTED ........................................................................................................................................... 5
1.3 GOOD HABITS .................................................................................................................................................. 8
1.4 KEY ELEMENTS IN THE HYSYS WORKSPACE .................................................................................................... 8
1.5 UNIT OPERATIONS ............................................................................................................................................ 9
1.6 SELECTING INPUTS TO USE ............................................................................................................................. 14
1.7 DEALING WITH THE SPREADSHEET FUNCTION ................................................................................................ 16
1.8 USEFUL NOTES ............................................................................................................................................... 18
2 CHNG 2801 (FLUID MECHANICS) .................................................................................................................. 20
2.1 FLUID MECHANICS INTRODUCTION ................................................................................................................ 21
2.2 PIPES .............................................................................................................................................................. 23
2.3 USING CASE STUDIES ..................................................................................................................................... 30
2.4 PUMPS ............................................................................................................................................................ 39
2.5 ENERGY BALANCES........................................................................................................................................ 46
2.6 MASS TRANSFER ............................................................................................................................................ 49
2.7 CHANGING SYSTEM PROPERTIES IN THE MIDDLE OF A SESSION ..................................................................... 52
2.8 SIMPLE REACTIONS ........................................................................................................................................ 54
3 CHNG 2804 (THERMODYNAMICS) ................................................................................................................ 56
3.1 THERMODYNAMICS INTRODUCTION ............................................................................................................... 57
3.2 GAS COMPRESSION......................................................................................................................................... 57
3.3 ITEM TABLES .................................................................................................................................................. 62
3.4 GAS EXPANSION ............................................................................................................................................. 64
3.5 POWER CYCLES .............................................................................................................................................. 66
3.6 HYSYS STEADY STATE CONTROLS (SET/ADJUST/RECYCLE) .......................................................................... 74
3.7 REFRIGERATION AND AIR CONDITIONING ...................................................................................................... 74
4 THERMODYNAMIC PACKAGE CHOICES................................................................................................... 82
4.1 PACKAGES INTRODUCTION ............................................................................................................................. 83
4.2 VLE SIMPLE SELECTION ................................................................................................................................ 83
4.3 THERMODYNAMIC PACKAGES ........................................................................................................................ 85
4.4 BAD THERMODYNAMIC PACKAGE EXAMPLES ................................................................................................ 93
5 CHNG 2806 (ANALYSIS PRACTICE 2) ........................................................................................................... 95
5.1 ADDITIONAL 2ND YEAR HYSYS UNIT OPERATIONS ......................................................................................... 96
5.2 PHASE SEPARATORS ....................................................................................................................................... 96
5.3 BASIC DISTILLATION CONCEPTS (COMPONENT SPLITTER) ............................................................................. 97
5.4 AIR COOLERS ................................................................................................................................................. 99
6 INTRODUCTION TO 3RD YR........................................................................................................................... 100
6.1 MORE UNIT OPERATIONS .............................................................................................................................. 100
6.2 COMPONENTS FILTERS ................................................................................................................................. 102
7 CHNG 3801 (REACTION ENGINEERING) ................................................................................................... 103
7.1 REACTION ENGINEERING INTRODUCTION..................................................................................................... 104
7.2 HARDER DISTILLATION ................................................................................................................................ 107
8 CHNG 3802 (PROCESS CONTROL)............................................................................................................... 111
8.1 LINKING DRIVE SHAFTS ................................................................................................................................ 112
8.2 DYNAMIC MODE .......................................................................................................................................... 112
8.3 ENTERING DYNAMIC MODE ......................................................................................................................... 117
8.4 SIMPLE DYNAMIC EXAMPLES ....................................................................................................................... 119
8.5 CONTROLLERS .............................................................................................................................................. 120
8.6 CONTROLLER EXAMPLES ............................................................................................................................. 122
9 CHNG3806 (PRODUCTS AND VALUE CHAINS) ........................................................................................ 125
9.1 STREAM PROPERTIES .................................................................................................................................... 126
9.2 DETERMINING WHAT SOLIDS OPERATION TO USE......................................................................................... 128
9.3 OPERATIONS ................................................................................................................................................. 129
10 ADVANCED MATERIAL ................................................................................................................................. 131
10.1 PIPESYS ........................................................................................................................................................ 131
11 NOT SO CLEVER APPLICATIONS OF HYSYS .......................................................................................... 134
2
1 Intro to Hysys for 2nd year
This first section of the guide has the descriptions of some unit operations and the meaning of the
most common warnings together with the reason for the different colours used for operations, lines
etc. This section should be useful if there are problems with the use of Hysys.
3
1.1 Why use Hysys? (or Simulations)
Hysys is a simulator that was designed for chemical engineers particularly in the field of
petrochemicals. However over the years the package has grown to handle aqueous systems and
particle flows.
The simulation is only as good as the assumptions made, correlations, thermodynamic packages and
data available. That means an appropriate thermodynamic package needs to be chosen and your
thermodynamics text books will be a useful guide for this.
Simulations are used in two major areas, these are Design and Operation. Simulators are useful in
design due to the high speed of calculations on sizing, costing, timing and error analysis. The
Operational side of simulators are in optimisation of plant maintenance, feedstock costs, chemical
reactions and rating equipment. Rating equipment is determining if the equipment performs as
desired. Another part of operational simulation is to remove bottlenecks in the process by
experimenting with the chemical or energy pathways to give a more efficient process.
Properly used simulations save time and money in day-to-day operation of chemical systems. Hysys
is a very powerful simulation tool, but must be operated by someone that has the correct
understanding of the background knowledge that is used within Hysys. Such as what fluids package
to use and when, how many recycle streams are possible, and knowing when a unit operation is too
large for a real life construction to take place.
These are all examples of things that Hysys cannot give us because Hysys is only a big calculator
and is not designed to make the decisions for us. Hysys has 3 major levels of functionality; these are
initial flow sheeting with simple mass and energy balances, basic equipment sizing and design, and
dynamic simulations. The operator needs to understand the key concepts of design and optimisation
to use this tool effectively. For much of this book only Flow sheeting and some sizing will be
undertaken.
4
1.2 Getting Started
1.2.1 Can the Process be simulated using Hysys?
Hysys has a large range but by no means all of the chemicals or unit operations that are available to
chemical engineers, so we need to determine if the process can be simulated.
Before using a flow sheet it is best to write out and chemicals, reaction paths, operations and what
operating conditions are necessary.
In general advanced materials and Bio-chemicals/ Organisms are not catered for in Hysys. Unit
operations that are missing may be estimated using the simple pallet.
The next thing that needs to be determined is what fluid package to use. There will be a guide in
Section 4 Thermodynamic Package Choices, up to this point one will be given to you to use.
Programs
AspenTech
Aspen Engineering Suite
Aspen HYSYS
Aspen HYSYS
This will bring up a blank window that looks like the picture
Figure 1-1 to the right. To start a new file, click the “new file” Figure 1-1: The Starting Screen
button (B1). Then a new screen will pop up which looks like
Figure 1-2 below.
B2
B3
Tabs
5
From this screen all of the workings behind the simulation may be assembled such as the
components or materials, fluids packages, Hypothetical components, reactions and others. These are
the key factors in any chemical process simulation. There is a list of tabs towards the bottom of this
window, which allow each different function to be explored. In order to return to this menu at any
time simply click on the “Enter Basis Environment” button (B2)
Let’s start simple, click on the “Add” button (B3) then you will see another new screen pop up.
This is shown below in Figure 1-3.
At this screen it is possible to use the in built search engine for a material that will be used in the
simulation.
For the demonstration below air was chosen and added into the “match” box (R1). This found the
material in the list and the “<--- Add Pure” Button (B4) was pressed when air was selected. To
delete a component from the list just highlight the wring component and press the “Remove --->”
button (B5) and try again.
When you have finished, simply close the window. This may be done using the button at the top
right of the window (x).
NOTE: Air is a combined property set for an Oxygen/Nitrogen mixture. If oxygen is required define
the air as the multi-component system with Oxygen and Nitrogen. This is particularly important for
reactions such as combustion.
R1
B4 Close
List of
added
material
B5
List of
Materials
Next a fluid package must be selected. In order to do this we need to find the Fluids Package tab on
the basis manager screen (Figure 1-2). The screen should now look like Figure 1-4 below. From this
screen you are able to view any active fluids packages and create some new ones. To create a new
fluid basis, simply click the “Add” button (B6).
6
B6
Current
B7
The following window will appear once this is done. This can be seen below in Figure 1-5.
B7a
If you are unsure of which Fluids Package to choose, click on the ‘Launch Property Wizard’
Button (B7a). This will bring up a new window that looks like the one in Figure 1-6 below. Follow
the prompts until a few options are given to you. Commonly used packages are Peng-Robinson for
general purpose, ASME Steam or NBS Steam for water systems and PRSV or UNIQUAC for polar
mixtures such as Water/ Ethanol. There are a variety of Fluids packages in Hysys, their uses will be
discussed later in Section 4.
7
1.3 Good Habits
There are some good habits to get into in order to make life a little easier for other group members,
tutors and yourself to down the track. These include having most of the streams flow in the same
direction, generally left to right and top to bottom, the exception being recycle streams and cyclic
systems. This may be achieved by placing the units on the page before any streams are added.
Another approach is to draw out the layout by hand. It is also a good idea to give names to the
units/objects to help determine what things are.
For larger and more complex configurations it is easier to label streams with designated letters such
as “S” for material streams and an Individual 3-digit number for each letter. It is also a good idea to
label from the mainstream and outwards from there as you go along. Try to keep the different types
of energy separated; (I use ‘Q’-Electrical, ‘H’-Heat), this is because Hysys can’t differentiate
between types of energy for you. Mixing up the energy types may cause a violation in the second
law of thermodynamics.
B8
R2
B9
R4
R3
8
1.5 Unit Operations
Hysys has a wide range of unit operations and they may be found on the tool bar (R2) above. In
each section of this there will be an illustration of the position of the item on the toolbar shown on
the right of the screen. The commonly defined variables are highlighted.
NOTE: These are not related to Temperature. A method for avoiding the mix up Figure 1-9:
Energy Stream
is discussed above in Section 1.3.
These are usually placed from inside the operation that requires them. There are only a few
specifications that can be made in these. However these items are usually left alone and are
calculated from unit operations. The energy stream is used in two ways; finding the required energy
or the effects of a certain amount of energy, (temperature and pressure changes). The location is
shown as a RED arrow on the toolbar. (Figure 1-9)
• Energy Flow
Figure 1-10:
Tank/ Separator
9
• Inlet Delta P
• Tank Geometry
• Tank Type
• Tank Volume
• Reactions
• Vapour Outlet Delta P
• Heat Loss Type
• Liquid Level (%)
The commonly used parameters are the Inlet and Outlet Delta P, Tank Type/Geometry and
reactions.
The Heater and cooler are simple in comparison to the heat exchanger units that Hysys has to offer.
These simple operations are important for initial heat exchange design of any plant. These functions
may be found where indicated on the right. Blue is cooler, Red is heater, (Figure 1-11). For later
stage design it is better to replace these couples with the “Heat Exchanger” unit, this is a much more
detailed of the heat exchanger with construction materials taken into account.
The available specifications for these units are listed below. It is better to define most of the
variables in external streams leaving only one variable left to be calculated.
• Delta P
• Delta T
• Duty/ Heat
• Heat Loss
• Various other variables that are not necessary for 2nd and 3rd year Hysys
The most commonly used variables are the Pressure and Temperature change.
There are several different variables that may be defined in this unit, as it is very flexible in its use.
These will not be shown here due to the complexity and quantity. The main purpose of the heat
10
exchanger is to transfer heat efficiently from one stream to another. The heat exchanger function
simulates heat loss and transfer rates for sizing options and handles 2 stream sets; these are
described as the Shell and Tube sides. (The LNG heat exchanger handles multiple streams and has
complex design options such as layering).
These heat exchanger functions do detect temperature crossovers and will even warn when the Ft
Factor is too low. The heat exchangers design or configuration may be changed to fix this type of
error. In practice you do this by having 2 or more exchangers. For simplicity you can increase the
‘Tube Passes per Shell’ or change the ‘Shell TEMA Type’ to ‘F’ as an approximation to this.
It is not recommended to alter any other parameters until they are understood, simply leave the
assumed figures. These other parameters will be discussed later on, usually during the CHNG 380x
courses.
1.5.6 Pump
The Pump unit operation is used for liquids or slurries only. There is a lot
you can do with a pump but we only want to concentrate on the basics for
now. In complex dynamic design you can model the pump curves and
motor efficiency. In the following examples we will go through how to
define a pump. The specifications that are available for simple calculations
are listed below. This unit operation may be located on the toolbar at the
indicated location. (Figure 1-12)
• Delta P
• Duty/ Power Figure 1-12: Pump
• Pump Curves
• NPSH
• Adiabatic Efficiency (Default value of 75 %)
The pump is commonly defined by flows Delta P and Power.
11
1.5.8 Gas Pipe/ Pipe Segment
A gas pipe/ pipe segment is a functional group in Hysys that simulates
pressure drops and flow properties for pipe systems, even allowing for
roughness properties of basic construction materials. The piping system may
be defined using these functions including heat transfer, sizing, materials and
even bends in the tube. This is useful for fluid considerations in the process
for pumping requirements and overall design. The location on the toolbar is
indicated on the right. The one with the ‘G’ on it is the gas pipe segment.
(Figure 1-14)
Figure 1-14: Pipe
These are summarised below.
Segments
• Ambient Temperature
• Construction Material
• Delta P
• Length
• Diameter
• Schedule Number
• Overall Heat Transfer Co-Efficient
• Calculation Method
The most commonly defined variables are the pipe length, elevation, Schedule number, Material
and Nominal Diameter.
1.5.9 Valve
The valve has limited uses in flow-sheeting, but is useful in Fluid Dynamics
and in a refrigeration cycle explained below in Section 3.6; apart from this the
valve is an important operation that is used in commonly in Dynamic mode,
primarily for control. The considerations for a simple valve are listed below.
The use of ‘Relief Valve’ will be explained in Section 8. The valves are
located at the indicated position on the toolbar. (Figure 1-15)
• Delta P
• Valve Position
The valve position is assumed to be 50 % open.
Figure 1-15:
1.5.10 Mixer/ Tee Simple Valve
These are very simple unit functions that combine and split streams.
12
1.5.10.2 The Tee
The Tee splits everything given the required flows or ‘splits’, that is a ratio of flow one way or the
another. This is not a type of separator/splitter but similar to a pipe junction. The Tee does not split
energy streams. The Tee splits a consistent flow into the desired ratios for easier heat regeneration
considerations and simple recycling options.
The location of these on the toolbar is indicated on the right. (Figure 1-16)
1.5.11 Spreadsheet
The spreadsheet is not a functional unit operation. The spreadsheet function is
not as complex as Microsoft Excel and does not have as many functions but
acts in the same way. Spreadsheet is able to do simple maths calculation;
addition etc. Spreadsheet applications should be understood before
progressing to the more complicated ‘Case Study’ function or other
complicated dynamic control. This item may be found near the base of the
toolbar. Its position is indicated on the right. (Figure 1-17)
Figure 1-17:
Spreadsheet
13
1.6 Selecting Inputs to Use
The user needs to get a feel of what inputs are required and what they need to find. In Hysys this is
quite difficult. In order to solve problems easily, set out the question and variables on paper so that
you know what there is to use and what it is that you need to find. This makes solving the problem a
lot easier as there is no uncertainty of what needs to be done. There are some worked examples
further on that show how easy this makes the process. Don’t try to overcomplicate the problem
there are simple answers to most problems. For example using a the heating/ cooling function as
heat exchangers until there is enough information to replace it with the proper heat exchanger
function.
This rule applies to not only each operation but the entire system as a whole. If the solver is
running, Hysys will solve each operation once the DoF’s=0. The spreadsheet can be used to do
calculations and export values to define some of the parameters. Therefore a degree of freedom can
be removed. Many warnings tell you to add a specification, it is best to follow the instructions. If a
warning tells you it cannot solve or is ‘Over Specified’. Try to understand what variables will solve
the problem. These are all degree of freedom errors which will be described below. The more
complex operations such as distillation columns will require a lot of specifications will tell you how
many specifications or degrees of freedom available to fill.
14
Figure 1-18: The Properties Menu View
15
1.7 Dealing with the Spreadsheet Function
1.7.1 Importing Information
The first step is to set up the spreadsheet by placing it onto the desired worksheet.
The next step is to open the object, by double clicking on the object.
Figure 1-19 shows the variables that are being imported and exported.
To input a variable, click on the “Add Import” button located on the right hand side of the top
table. This will bring up the screen shown in Figure 1-20 below. There are multiple options on this
screen, so select the variable from left to right.
16
B10
Figure 1-21: A blank spreadsheet Figure 1-23: The data in the spreadsheet
17
1.8 Useful Notes
1.8.1 Colours of Items
An important thing to look for is the colour of items in the workspace and in the item windows. The
various colours and meanings are listed below in colour code for easy reading.
YELLOW strip means there is an error or something needs to be defined. This usually includes
instructions or the type of error.
GREEN strip means the item is ready and working
1.8.2 Warnings
These are displayed in the status strip of an item screen and in the ‘Object status list’ (R3) in Figure
1-7 above. A list of common warnings and solutions will be listed on the following page. As a rule
of thumb follow any instructions given by Hysys, or remove some specifications and start again.
This allows for the option of seeing where the problem stemmed and if specifications were not
needed. To avoid most complications either add in all of the operations and streams then connect
them up as start defining parameters, or add in the operations one by one and define the parameters
as you go along the lines.
18
1.8.2.1 Overdefined
This is when you have supplied too many specifications.
Solution
Remove at least one specified variable.
19
2 CHNG 2801 (Fluid Mechanics)
This section is designed to assist in the learning of the basics of Fluid Dynamics, heat and mass
transfer, and reaction engineering. This section also gives an introduction into the abilities of Hysys
in terms of piping, pumping, heat integration, and reaction techniques.
20
2.1 Fluid Mechanics Introduction
Fluid mechanics is a key area of chemical engineering and every engineer need to understand
pumping and piping, pipe and pump costs, insulation, size, fittings and materials requirements are
essential. Hysys could estimate a range of different piping and pumping calculation and correlation,
such as pipe scoping calculation and pump curve integration.
2.1.1 Streams
The following section will be a continuation from the example in Section 1.2.2. Streams are the
most used item in the program, and the easiest to manipulate. To use one simply add one to the
workspace and simply double click on it. This will bring up the following screen in Figure 2-1
below.
Define the system by the specifications below in Table 2-1, and then we can proceed. In order to
define the stream, try to follow the instructions in the yellow strip at the bottom of the window.
For this message, (Unknown Composition), click on ‘Composition’ located in the menu on the left
of the box; this will bring up a new view in the same box; this is displayed in Figure 2-2 below.
Entering a fraction into one of the materials will bring up a dialogue box similar to the one shown in
Figure 2-3 located over page.
From this screen define the composition of the stream and type ‘Enter’ or click ‘OK’ to finish. You
will notice that a new message pops up, (Unknown Temperature), to define the temperature simply
click on the “Conditions” Menu item located at the top left of the window, this will bring up the
table shown below in Figure 2-1.
Insert a temperature of 25 oC, a new message will appear at the bottom of the window, (Unknown
Pressure), Insert 1 into the “Pressure” box and select ‘atm’ from the drop down menu that appears,
this is shown in Figure 2-4 below.
Notice that Hysys will automatically change the units back into the standard SI units, which has
been set as default. The next message will say Unknown Flowrate; this is where things become
difficult. There are three (3) different possible flow options, enter 60 into “Mass Flow” to see what
happens. All of the undefined data will be calculated and that data will be filled in with black text.
NOTE: that all of the defined data is in Blue as shown below in Figure 2-5.
21
Menu
Composition
22
2.2 Pipes
One of the first things you will notice at any chemical plant or building is the large number and
variety of pipes. Hysys is a very useful in performing calculations around pipes. There will be a
series of walkthroughs and tutorials that will assist in learning fluid mechanics subject material.
PIPE WORKSHOP
The process of finding the Reynolds number and frictional pressure drop is shown below. Firstly we
can do some hand calculations as shown in class. Work out the Friction Factor from a chart or
formula (Equation 2-1) and Reynolds Number (Equation 2-2) based on the following parameters in
Table 2-3. The next step is to work out the frictional pressure drop along the pipe. Remember there
are several different definitions of Friction factor that are used in different books. Hysys does not
give us a friction factor but it gives a friction profile along the pipe length.
Equation 2-1: Swamee-Jain equation for Friction Equation 2-2: The Reynolds Number
Factor ρvD
0.25 Re =
f = 2
µ
ε 5.74 where :
log10 3.7 D + Re 0.9
ρ = Fluid Density
where : v = Fluid Velocity
f = Friction Factor D = Characteristic Length (Inside Diameter)
ε = Absolute Internal Pipe Roughness µ = Fluid Viscosity
Re = Reynolds Number
D = Characteristic Length (Inside Diameter) Table 2-3: Data for hand calculations
Parameter Value Units
Density 1000 kg/m3
Table 2-2: The Hysys Setup Viscosity 1x10 -3
Pa.s
Components Fluids Package Pipe Inside Diameter 26.64 mm
Water ASME Steam Pipe Outside Diameter 33.40 mm
Height Change 0 m
Pipe Length 10 m
Roughness 1.4x10-5 m
Flowrate 8 m3/hr
Then insert a Pipe unit. Next we need to define the streams as shown in Table 2-4 below. Do not
worry if you do not understand where to put some of the data, it will be illustrated below. Notice
that Hysys will never ask for Physical Properties for any chemical that is being used. This is
because they are being calculated from the selected fluids packages. To view the physical properties
of a stream simply go to the “Worksheet” tab, “Properties” menu. You will notice that the values
of density and viscosity are a little different to the assumed values above. However for this example
those assumptions are sufficient for a close answer.
23
Table 2-4: The data to enter for the pipes pressure drop
Item TAB/ Menu Parameter Value Units
S-100 Worksheet/ Conditions Temperature 25 oC
Pressure 1.5 atm
Vol. Flow 8 m3/hr
Worksheet/ Composition Water 1
S-101 *Worksheet/ Conditions Temperature 25 oC
*NOTE: This specification will be discarded once heat transfer is discussed. It will
be calculated with the heat transfer specifications defined.
Pipe-100 Design/ Connections Inlet S-100
Outlet S-101
Energy H-100
Rating/ Sizing Fitting/Pipe Pipe
Length 10 m
Elevation change 0 m
Material Plastic Tubing
Rating/ View Segment Pipe Schedule 40
(B12) Available Diameters 25.4 mm
Increments 20
The information that may be difficult to enter from the table above is the sizing and segment
information; the following instructions will guide you through these.
These may be entered by clicking on the “Append Segment” button (B11) and then the segment
information on the left of Figure 2-6 may be entered. Do not enter the Diameters. To finalise the
pipe segment click on the “View Segment” button (B12), doing this will bring up the window on
the right. Enter the pipe schedule and the table at the base of the window will be filled out. Select
the top left value and click “Specify” (B13). From here the pipe should solve.
B12 B13
B11
Next we need to see the results for the pressure drop and other calculations that Hysys has
completed.
To do this, go to the ‘Performance’ Tab, and then click on “View Profile”, this action will bring
up a new window filled with data that Hysys has calculated. Maximise this window and find the
relevant data such as ‘Length’, ‘Liquid Re’, ‘Pressure’, ‘Friction Gradient’ and ‘Liquid Velocity’.
Re =120,000, Friction Gradient ~= 5.99 kPa/m, Liquid Velocity ~4 m/s. This window is
demonstrated below in Figure 2-7.
24
Figure 2-7: Preview of the View Profile Table
Notice that the number of rows or results is the same as the number of increments within the pipe.
• Compare the Hysys Reynolds number, frictional gradient, pressure drop and liquid velocity
values to the ones you calculated.
• Comment on how the pressure drop and flow calculations may be different from the ones
done by you.
25
2.2.2.2 Pipe Characteristics
These are important, Hysys defines most of these based on materials selection and other user
defined variables. It is possible to define these variables from manufacturer’s specifications in
Hysys, the process is simple enough. Just input the new variables into the required pipe segment
windows. This is for later stages like rigorous pipe design; this may be used in 4th year Design.
Typical Properties include Thermal Conductivity, Roughness (absolute) and Specific Dimensions.
2.2.3 Valves
This section will introduce the different types of valves, where to use them and why.
Most of this information will not be necessary until later when the design of valves is required.
2.2.3.2Gate Valves
Best Suited Characteristic: Quick Opening
Recommended Uses:
1. Fully open/closed, non-throttling
2. Infrequent operation
3. Minimal fluid trapping in line
1
Sourced from www.cheresources.com/valveszz.shtml
26
Advantages: Disadvantages:
1. High capacity 1. Poor control
2. Tight shutoff 2. Cavitate at low pressure drops
3. Low cost 3. Cannot be used for throttling
4. Little resistance to flow
Recommended Uses:
1. Throttling service/flow regulation
2. Frequent operation
Advantages: Disadvantages:
1. Efficient throttling 1. High pressure drop
2. Accurate flow control 2. More expensive than other valves
3. Available in multiple ports
Recommended Uses:
1. Fully open/closed, limited-throttling
2. Higher temperature fluids
Advantages: Disadvantages:
1. Low cost 1. Poor throttling characteristics
2. High capacity 2. Prone to cavitation
3. Low leakage and maintenance
4. Tight sealing with low torque
Recommended Uses:
1. Fully open/closed or throttling services
2. Frequent operation
3. Minimal fluid trapping in line
27
Advantages: Disadvantages:
1. Low pressure drop 1. High torque required for control
2. High capacity 2. Prone to cavitation at lower flows
3. Good flow control
4. Low cost and maintenance
Sometimes we need to find out the natural heat loss through a length of a pipe. This is important
particularly if the liquid is either much hotter or much colder than the ambient conditions such as
Cryogenics (Super cold) and Super-heated fluids (such as steam in a Rankine Cycle).
From the pipe example, above in Section 2.2.1.1 (Pipe with ND 1 inch, Length 10 m, flowrate 8
m3/hr), remove the outlet temperature specification, and change the Inlet Temperature to 60 oC.
Next go to the ‘Rating’ tab, ‘Heat Transfer’ menu. The view in Figure 2-8 below should appear.
Click on the ‘Estimate HTC’ (HTC is Heat Transfer Coefficient) button (B17). The view will
change to the one in Figure 2-9 below.
Select the options in Figure 2-9 below, select ‘Include Pipe Wall’, ‘…Inner HTC’, ‘…Insulation’
and ‘…Outer HTC’ to include these specifications in the heat transfer calculations.
Click on the ‘Segment HTC’ button (B16). Enter 25 oC in every available cell of the ‘Am. Temp.’
column. (Alternately if you select ‘Global’ in the estimation screen the Ambient Temperature should
be entered into the ‘Overall HTC’ (B15) screen).
NOTE: Ambient Temperature is the temperature of the surroundings; 25oC for air is a good
assumption, but it depends on where your plant is situated, the time of day/year and other heat
sources.
The pipe should now solve. Go to the ‘Heat Loss’ screen again by clicking the ‘Heat Loss’ Button
(B14). Notice that the Heat loss has been calculated. Check out the other specifications in the outlet
stream to see the effects. Compare this with the results of the example in Section 2.2.1.1.
28
Equation 2-3: The Sieder-Tate Correlation
0.14
µ
Nu = 0.027 × Re 4p/ 5 Pr 1 / 3
µw
Where :
B14 B15 B16 B17
Nu = Nusselt number
Re = Reynolds Number
Pr = Prandtl Number
µ = Viscocity of the Fluid
µ w = Viscosity of water at STP
Limitations :
Figure 2-8: The Heat Transfer\ Heat Loss screen 0.7 ≤ Pr ≤ 16,700
Re ≥ 10,000
L/D ≥ 10
29
2.3 Using Case Studies
Case studies ability to compute multiple simulations is an important part of Hysys. This lets you
compare the effects of changing operating conditions. It is best to start with only one or two
variables.
Figure 2-11: The case study variables screens Figure 2-12: The case studies tab and setup window
Then click on the ‘Case Studies’ tab on the ‘Data Book’ window. This should change the view to
the one at the base of Figure 2-12. From the new screen click ‘Add’ then your variables will appear.
Select which variables are independent (the ones that you want to change) and the dependent
variables (the ones that are calculated- These usually have the independent box crossed/ shaded
out). Then click on ‘View’, located below the ‘Add’ button. A new window should appear like the
one on the top half of Figure 2-12. Enter the low and high bounds on the independent variables,
including a step size, 5 to 10 steps is enough to start with, the step size can be narrowed with the
field later on. Remember the more steps there are the longer Hysys will take to find the values but
will give a smoother curve.
To finish up click on ‘Start’, Hysys will take a few seconds to calculate the case study.
To view the results, click on the ‘Results’ button near the bottom left of the window.
This will bring up a table or a graph representation of the data in a new window. (Maximise this
window for the best view)
To switch between the two click the tabs at the base of this window.
30
PIPE TUTORIALS
For all of these pipe tutorials the only component will be Water and the fluids package is ASME-
Steam, there are no elevation changes, and assume no heat loss.
For all of these examples the schedule is 40.
• System A simulates a straight piece of pipe.
• System B simulates a pipe with a change in diameter and back
• System C simulates the effects of bends and elbows
• System D simulates Tee’s as bends and stream splitting.
• System E simulates a simple Pipe Network
• System F (not shown) simulates the different valves
NOTE: These are system curves which may be used for the pump systems and pump selection later
on.
NOTE: Some results may need the assistance of the spreadsheet functions
• Give a discussion based on the head loss calculations and determining the friction factor.
31
Build up the pipe systems (A, B and C) described below.
32
Pipe System ‘C’ contains:
NOTE: Remember to use the ‘Coupling/Union’ segment for any multi diameter joints mentioned.
Have the internal diameter the same as the smaller pipe diameter
Table 2-9: Table of Answers for system 'C'
Parameter Set 1 Set 2 Set 3 Set 4 Set 5
Hysys Head Loss
hv (m)
Flow (L/min) 4 16 28 40 52
& 3
Flow V (m /s)
Flow Speed
v (m/s)
Pipe Roughness (mm) 1.4e-3 1.4e-3 1.4e-3 1.4e-3 1.4e-3
Reynolds’ Number
Re
Pipe Friction Co-efficient
(Blasius Eqn.) λ
Pipe Friction Co-efficient
(Swamee Eqn.) λ
Calculated Head Loss
hv (m)
Difference in hv %
33
Tees
Open the file specified by the tutor. (…/PipeTees.hsc)
NOTE: The effects are negligible to pressure drop, also shown in Table 2-10 below.
• Plot the system curve (Flow 4-52 L/min) and compare the curve with the ones from A, B
and C.
Pipe Network
Open the file specified by the tutor. (…/PipeNetwork.hsc)
The object of this tutorial is to see the effects of different types of valves on the system.
Notice that the system could not be defined in a single pipe unit. This is because the pipe segment
cannot handle split flows. Set the split pressure drops and then split the flows externally. Plot the
system curve (Flow 900-1005 L/min) and compare the curve with the ones from A, B and C. Make
sure the outlet pressures are as close to 1 atm at all times.
NOTE: The pressures from all incoming streams to the mixers are assumed to have equal
pressures. In practice inlets will flow in the reverse direction if the pressure in that stream is low,
(predicted by Hysys). The split ratios that are to be used in the inlet Tee (Tee-100) are 0.5500-
0.5512 (recommended running at 0.5510). These are near the system limits for the inlet splits.
• Discuss why the stream splits at Tee-100 are so narrow for the system to function. Use the
illustration above to help if required.
• Change set the flow at 1000 L/min and run a study for the system curve on the inlet pressure
from 3.4 atm to 100 atm.
34
Valve Type
Set up a pipe segment in Hysys.
Set the inlet and outlet Temperatures (25 oC) and outlet Pressure (1 atm).
Replicate (copy) the simulation with the following valves replacing the ‘Gate Valve: half’:
• Insert a ‘Butterfly Valve: angle 40o’
• Insert a ‘Angle Valve: 45 deg open’
• Insert a ‘Globe Valve: Half’
• Insert a ‘Diaphragm Valve: 60o’
Plot a system curves for the defined systems.
2. Swap the ambient temperature with the inlet temperature. (inlet = 25 oC, ambient = 80 oC)
Write down the pressure drop, temperature drop and energy gain.
Now run a case study the effect of flowrate (0.1 – 50 L/min) on Delta P and Delta T and the
Heat stream value.
3. What variables are required to work out the flowrate required to remove a set heat
requirement (Question 1). The answer should be based on 10 kW. With a temperature approach
of no less than 10 oC (i.e. outlet temp must be more than 10 oC greater than the set ambient
temperature), and the system does not go below atmospheric conditions. Copy the case study
results down and hand them in.
35
TUTORIAL RESOURCES
Equation 2-4: The Pipe Tutorial Equation Sheets
Flow Speed
4V&
ν =
πd 2
Pressure Loss
λL pipe
∆P pipe = ρv 2
2d
v12 v2
∆P fitting = ζρ = (VH ) ρ
2 2
1 1
ρ
∆Ptotal = Σ ∆P pipe (i ) + Σ ∆P fitting ( j ) − ∆P pump + (v12 − v 22 ) + ρg (h1 − h 2 )
i j 2
NOTE : To Convert between Delta Head and Delta Pressure use the pressure equation.
∆P = ρg∆h
REYNOLDS' Number
ρvd
Re =
µ
Blasius Friction Factor (smooth pipe assumption only)
0.3164
λ=
4
Re
Colebrook Friction Factor
−2
2.51 0.27ε
λ = 2 log 10 +
d
Re λ
Swamee - Jain Friction Factor
0.25
λ=
2
ε 5.74
log 10 +
3 .7 d Re 0.9
Co - efficient of resistance (with diameter change factor)
∆Ptotal d 2 λ1 l 1 d 2 λ 2 l 2
ζ =2 − 1 − 4 − 4
d d + d
ρv 22 d
1 1 1 2
Co - efficient of resistance (without diameter change factor)
∆Ptotal λ2l 2
ζ =2 −
ρv 22 d2
Where :
ε = Absolute Internal Pipe Roughness
d = Characteristic Length (Inside Diameter)
h = Relative Height
µ = Fluid Viscosity
∆P = P2 -P1
ρ = Fluid Density
v = Fluid Velocity
VH = Velocity Heads
36
Table 2-10: VH's used by Hysys for fittings (Perry’s Chemical Engineering handbook)
Type of Fitting or Valve (VH), K Type of Fitting or Valve (VH), K
45° elbow, Plug disk
Standard 0.35 open 9.00
Long radius 0.20 ¾ open 13.00
90° elbow ½ open 36.00
Standard 0.75 ¼ open 112.00
Long radius 0.45 Angle valve
Square or mitre 1.30 Open 2.00
180° bend 1.50 Y or blow-off valve
Close Return 1.50 Open 3.00
Tee Plug cock
Standard, along run, branch blanked off 0.40 θ = 5° 0.05
Used as elbow, entering run 1.00 θ = 10° 0.29
Used as elbow, entering branch 1.00 θ = 20° 1.56
Branching flow 1.00 θ = 40° 17.30
Gate valve θ = 60° 206.00
Open 0.17 Butterfly valve
¾ open 0.90 θ = 5° 0.24
½ open 4.50 θ = 10° 0.52
¼ open 24.00 θ = 20° 1.54
Diaphragm valve θ = 40° 10.80
Open 2.30 θ = 60° 118.00
¾ open 2.60 Check valve
½ open 4.30 Swing 2.00
¼ open 21.00 Disk 10.00
Globe valve Ball 70.00
Bevel Seat Water meter
Open 6.00 Disk 7.00
½ open 9.50 Piston 15.00
Composition Seat Rotary (star-shaped disk) 10.00
open 6.00 Turbine-wheel 6.00
½ open 8.50 Coupling 0.04
Foot valve 15.00 Union 0.04
37
Figure 2-14: Friction Factor vs Reynolds number (Moody Plot)
38
2.4 Pumps
2.4.1 Standalone Pumps
For simple problems a pump may be used on its own. Give stream properties on either side of the
pump the system will solve. Firstly open up a Pump unit operation by placing one in the workspace
and double clicking on it. The view should be similar to Figure 2-15 below. There are a few
options that will create a solution in Hysys. Given 2 of the 3 variables it is possible to achieve the
other one. (POWER, FLOWRATE and DELTA P) Given an initial guess for an outlet or inlet set of
conditions such as temperature and pressure are required for an initial solution. The result is still the
same with these conditions changed.
NOTE: Alternatively to the outlet pressure being defined it is recommended to set the Delta P of
1atm in the ‘Design’ Tab, ‘Parameters’ Menu.
39
2.4.1.3 Finding Flow given Delta P and Power
From the example above remove the ‘flow’ specification in the inlet stream (S-100). Then add in a
Delta P across the pump. This may be done in one (1) of two (2) ways. Either define an outlet
‘pressure’ in the outlet stream (S-101) or define a ‘Delta P’ in the Pumps ‘Design’ tab,
‘Parameters’ menu.
The next step is to add a pump unit operation into the worksheet. Now define the variables in Table
2-12 below. Notice that all of the streams (S-101 in particular) do not need to be defined, and that
some of the properties that were required for the pipe are no longer needed. This is because systems
with more than one operation may take care of some of the variables for other operations.
40
If you attach all of streams up and define the parameters from the pump to the pipe you will notice
the system will not solve. Disconnect the pump from S-101 and set the flowrate and temperature in
the pipe outlet stream (S-102). The pipe segment will now solve on its own. Re-connect up the
pump and the pump will now solve. Remove all but the pressure specification in S-100. This is so
that if you change a parameter the system will not be over-defined. This will also solve if you set
the flow and temperature outlet without disconnecting streams.
Unlike the above example we cannot rely solely on the pipe to solve the problem first. From the
above example remove the Flowrate specification from S-102. This will cause the whole system to
become un-solved. Next we need to define the Power of the pump. This may be done in the
‘Design’ tab within the ‘Parameters’ menu, under ‘Duty’, Insert 2 kW.
Notice that Hysys does not want to solve the whole system. This is because Hysys does not do
calculations from the inside out; that is Hysys calculates from the ends. However there are some
functions that will allow for this type of calculation to take place, such as the Adjust function which
changes one variable to match a calculated value to a specification in the system. This will be
shown later in Section 3.5.4.
To short cut this solution Insert a pressure of 4.5 atm in S-101 and remove the pressure specification
in S-102. The outlet pressure should solve to be 1.56 atm or 158 kPa while the flowrate should
solve to be 842 kgmol/hr. An iterative solution may be reached by manually changing the pressure
specification.
Try to solve the problem by modifying some values or by iteration. Use 4.5 atm as an initial guess
for the Pressure at S-101.
NOTE: Even though this solution path is possible it is not recommended. The pipe has less solution
pathways and should be solved first. It is fine if there is no pipe segment to use this path if the data
requires it.
41
NOTE: There are several figures that are important for the ease of curve creation. These are Speed
“RPM”, Maximum efficiency, Flow and Head.
Equation 2-5: With Impeller D held constant Equation 2-6: With speed N held constant
Q1 N Q1 D1
= 1 =
Q2 N 2 Q2 D2
2 2
H 1 N1 H1 D1
= =
H2 N2
H 2 D2
3 3
BHP1 N1 BHP1 D1
= =
BHP2 N 2 BHP2 D2
Where:
Q = Capacity, GPM
H = Total Head, Feet
BHP = Brake Horsepower
N = Pump Speed, RPM
When the performance (Q1, H1, & BHP1) is known at some particular speed (N1) or diameter (D1),
the formulas can be used to estimate the performance (Q2, H2, & BHP2) at some other speed (N2) or
diameter (D2). The efficiency remains nearly constant for speed changes and for small changes in
impeller diameter. 2
Click on ‘Add Curve’ and enter the coordinates of one of the Flow/ Head curves. This is not the
preferred option however, instead of entering all of the data by hand click on the ‘Generate
Curves’ button.
This will bring up a new window like the one in Figure 2-17 below. Define the variables off the
‘DinFlow’ graph.
Design flow is 32 m3/h, Design Head is 22.8 m, design efficiency is 60 %, Design speed is 1450
rpm. Leave the other values as they are. Click ‘Generate Curves’ when this is done.
2
Pump Affinity Laws, Perry’s Chemical Engineering Handbook, Seventh Edition, 1997, Table 10-7, page 10-25
42
Three curves will be generated and their windows will open up, close these. To see where the
system has placed the operating conditions on the pump, click on ‘Plot Curves’, look for the
‘RED’ dot.
If no red dot is currently in the window. Check the ‘Use Curves’ box and input a desired pump
speed, in the ‘Pump Speed’ Box.
NOTE: The efficiency plot is parabolic. (Hysys has a tendency to mis-label curves)
43
2.4.4 NPSH Inclusion
Net Positive Suction Head (NPSH) is the measurement of liquid pressure at the suction end of a
pump. Insufficient NPSH can cause cavitations to the pumps due to vaporisation. To avoid
cavitations, NPSHA must be equal to or exceed the NPSHR.
Net Positive Suction Head Available (NPSHA) is the total head available at the suction end of the
pump. In an enclosed suction tank, NPSHA can be increased by raising the level of liquid in the
tank, thereby increasing the suction pressure/head.
Net Positive Suction Head Required (NPSHR) is the NPSH required for the pump to function
properly. NPSHR is usually provided by the pump manufacturer and is generally specified in the
pump curve.3
NPSH is essential for basic and complex design. Hysys does not require this information in steady
state or normal mode. For Flow sheet development it really isn’t necessary but it is far more
important for Dynamics and complex design calculations. Hysys will not give warnings of pump
cavitation in steady state mode, but that is something that the user is required to establish. To enter a
NPSH curve into the pump go to the ‘Rating’ tab, ‘NPSH’ Menu. From here you can enter a curve
for the pump. Click ‘Add Curve’ there are two (2) data points possible here.
Hysys assumes a linear relationship, so two points are fine for most pumps. Add in the NPSH from
the DINFLOW curve. Once this is done simply close the window. Next, to activate the curves, click
on the ‘Enable NPSH curves’ check box near the top of the window. Then click calculate, notice
that the required NPSH is far less than the available NPSH. This is desired for every pump system.
For this system there is a potential for more available NPSH based on the pipe profile.
3
Hargrave Corporation Sdn. Bhd. 2007, http://www.hargrave.com.my/about_pumps.php?page=3
44
PUMP TUTORIAL
1. To see the effects of flowrate and the system curves from Section 2.4.3.2 (Pump Curves) above
on a standalone pump with, change the flow either side of an assumed position (200 L/min) and see
if you can maximise the pumps efficiency. (use 1 to 1000 L/min with a step of 100)
You should plot the curves of Flow, Head, Efficiency and Power using a case study and save the
results.
NOTE: Viewing the pump curves with the operating point while the case study is running is a good
way to see the results effects.
2. Work out how many of the pumps defined above running at 435 rpm, in series or parallel, are
needed for 3 atm at the outlet (that’s a pressure change of 2 atm) for 166 L/min.
NOTE: Do not define the outlet pressure, simply work out how many pumps are required for that
pressure change. SET THE FLOWRATE AND RPM.
What power requirement would be needed? What is the new efficiency? Comment on any
differences in power requirements. (HINT: Change the RPM in the curves menu. Then divide the
actual requirements by what you can achieve)
Comment on the significance of these results. (I.e. why does a small change in speed result in so
many more pumps being needed)
3. If we have a Pressure outlet Requirement of 3 atm what speed would the pump need to run at?
(HINT: using Q1 remove the Speed in the curves menu and set the outlet pressure)
4. Write down why NPSH is important and how to calculate it by hand. Try to find the NPSH
system boundaries for inlet pressure and flowrate. Remember no warnings will show in Steady
State mode.
5. In dot form write down where the effects of NPSH would be most prominent, i.e. what
applications of pumps does this problem most affect?
Hand the tutorial answers to the tutor at the end of the session.
45
2.5 Energy Balances
Energy balances are an integral part of chemical engineering. Energy comes at a cost and its use
around the plant needs to be understood.
NOTE: This bit gets confusing on occasion; the name of the Heater or Cooler is given based on
the stream they are acting on.
Once this has been done add in the material streams from the heater and cooler and only one energy
stream. Connect the common energy stream to both units. Then define the heater with air as the
only component water in the cooler. Set some inlet temperatures, pressures and flows (Heater: 25
o
C, 1 atm, 1 kgmol/hr) (Cooler: 80 oC, 1 atm, 1 kgmol/hr). Then set the units pressure drops to zero
(0). Setting one outlet temperature should solve the system (temperature Cooler out 50 oC).
Check that there are no poorly defined values. I.e. the temperature in the hot out is cooler than the
cold out/in. Then try the system again only set the cooler outlet temperature to 5 oC.
What is wrong with the system that Hysys will not acknowledge? (The second law of
thermodynamics is violated)
46
R6 R8
R7 R9
R10 R11
Insert some streams and move on to the Parameters page. A new view of the exchanger will appear
similar to the one below in Figure 2-21. Here it asks for pressure drop and ‘UA’ (U is the overall
heat transfer co-efficient while A is the heat transfer area) information; ignore the UA for now. UA
will be handled later on in 3rd year Heat exchanger design; this is because UA is related to the
materials used and the sizing of the exchanger.
There are currently four options in the Heat Exchanger Model drop down menu these are:
Exchanger Design (Weighted); this model approach simulates multi phase systems such as a
condenser. This model can only handle single component systems and assumes counter current
flow only. No Ft factor is considered in this model.
Exchanger Design (End Point); this model approach simulates linear heat systems (i.e. no phase
changes), other assumptions are the overall heat transfer coefficient and specific heats on both sides
of the exchanger are constant throughout the system. This simulation uses the standard Heat
exchanger design equations.
47
Steady State Rating; this model is required for rating the system, this mode requires the geometry
of the exchanger. This model is based on the End point model with the same assumptions.
Dynamic Rating; This will not be used in this booklet. This has a considerable more amount of
detail for rating a heat exchanger than the Steady state option.
NOTE: Hysys does assume sizes so make sure these are defined correctly.
For this example keep the default value of Exchanger Design (End Point); these assumptions are
fine if there is no phase change. Just define the streams surrounding the Heat exchanger leaving
only one variable. Hysys will calculate the remaining values and sizing information. To find the
sizing and other calculated/defined parameters are found within the radio buttons located in the
‘Rating’ Tab, ‘Sizing’ Menu, ‘Sizing Options’ (top left drop down menu).
Table 2-14: The trial runs for the heat exchanger couple.
Stream Variable Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Trial 6
Cooler In Temperature 200 oC 110 oC 110 oC 35 oC 80 oC
Pressure 1 atm 1 atm 1 atm 1 atm 1 atm 1 atm
Flow 0.5 kg/h 2.5 kg/h 25 kg/h 2 kg/h
Cooler Out Temperature 10 oC 1 oC 50 oC 30 oC 45 oC
o
Heater In Temperature 5 C 25 oC 25 oC 40 oC -10 oC 25 oC
Pressure 1 atm 1 atm 1 atm 1 atm 1 atm 6 bar
Flow 30 kg/h 0.5 kg/h 10 kg/h 1 kg/h 10 kg/h
Heater Out Temperature 110 oC 200 oC 200 oC 45 oC 25 oC
Heater Delta P 0 kPa 0 kPa 0 kPa 0 kPa 0 kPa 4 bar
48
2.6 Mass Transfer
Mass Transfer is an important part of chemical engineering. It is often treated by analogy to heat
transfer. Examples of mass transfer are evaporation of water to air, ammonia in air dissolving into
water.
2.6.1 Introduction
In this section we will be using ‘Antoine’ as the Fluids Package.
Have n-Hexane and n-Heptane as the components; insert a material stream into the workspace.
Set the Pressure at 2 atm.
n-Hexane Composition 0.4
n-Heptane Composition 0.6
NOTE: ONLY DEFINE THE VAPOUR FRACTION WHEN AFTER THESE BUBBLE OR DEW
POINTS.
49
2.6.2 Absorber
This unit operation is used to simulate absorption. Examples of absorption are scrubbing and gas
cleaning.
NOTE: You will notice the ‘page 1 of 3’ (R13) label at the base of the screen with the page title
R12
R13
Figure 2-23: The Absorber setup Page 1 screen Figure 2-24: The Absorber setup Page 2 screen
Simply define the Inlet and outlet stream names and the number of stages (R12).
Click ‘next>’ to continue to the next page, Figure 2-24, Define the pressures of the outlets (1 atm
for this example) and click ‘next>’ again.
Figure 2-25 should appear. You do not need to fill in anything here so just click on ‘Done’. This
should bring up the overall screen shown in Figure 2-26. If the inlet streams have been defined the
system will solve.
NOTE: Always have the liquid stream at the top of the absorber with the gas stream at the base.
50
Define the following parameters for the Ammonia Scrubber.
Table 2-16: The Parameters for the Air Water Ammonia Absorber
Item Tab/ Menu Parameter Value Units
T-100 Page 1 Top Stage Inlet S-100
Bottom Stage Inlet S-101
Ovrhd Vapour Outlet S-102
Bottom Liquid Outlet S-103
Number of Stages 12
Page 2 Top Stage Pressure 1 atm
Bottom Stage Pressure 1 atm
S-100 Design/ Temperature 25 oC
Conditions Pressure 1 atm
Flow 3.9 kgmol/s
Composition Water 1 mol fraction
S-101 Design/ Temperature 25 oC
Conditions Pressure 1 atm
Flow 1 kgmol/s
Design/ Air 0.98 mol fraction
Composition Ammonia 0.02 mol fraction
• Change the number of stages to two (2) on the design connections page and hit the run
button at the base of the window. What effect did this have on the recoveries of the
ammonia in the outlet streams?
• Now change the water flowrate to 1 kgmol/s. What effect did changing the flowrate have on
the ammonia recoveries?
51
2.6.2.3 Common Convergence Setbacks
PROBLEMS
There is usually a lot of trouble in converging (solving for a solution) using columns; the iterative
solution path will usually loop back on it self. These are generally caused by poorly defined
systems, i.e. flows too large in one direction, liquid-liquid transfer, a liquid stream defined as
entering the bottom of the column or Bad Fluids Package selection (described below in Section 4).
METHODS
In General find the correct flow ratio using a case study.
Check the compositions of the feed streams and if they are realistic for an Absorber to handle the
concentrations.
Look at the fluid package abilities. There are generally many choices for each application. It is best
to determine the package on known or expected results.
To go back to the ‘System Parameters’ or “Basis Environment” Find the button that looks like a
beaker; this is shown as a close up in Figure 2-28 below.
You will recognise all of the features here from Section 1. From here you can add, change and
remove system parameters such as components, Fluid Packages and reactions (refer to the next
section).
52
MASS TRANSFER TUTORIAL
We will be answering Question 3 of CHNG2802 Module 1 notes (page 10).
1. A liquid stream comprising (on a molar basis) 30 % benzene (B), 30 % toluene (T) and 40
% styrene (S) is at 1.5 atm and needs to be heated. By carrying out bubble-point
calculations, estimate the maximum temperature to which this mixture can be heated before
vapour begins to form. What would be the composition of this vapour?
2. Now we will alter the composition of the feed to determine the effects on the vapour
composition. Write down the results in the table below.
NOTE: The ratios are not actually mol. fractions, to get the mol fractions add up the ratios and
divide by the total to get a total fraction, i.e. 2:2:1=5 0.4:0.4:0.2, alternately you could enter
the ratio and hit ‘Normalise’.
3. Run a case study of the pressure (0.5-5.0 atm) on the system (i.e. each component vapour
compositions and bubble point temperatures).
4. Using an Absorber, determine the compositions of the outlet streams for an
Air/Ammonia/Water system using SOUR-PR as the Fluids package. Using the data already
in the table, fill out the missing data.
53
2.8 Simple Reactions
This section is an introduction to reactions in Hysys. Further work will be completed as part of the
third year subject material. The need to input reactions into Hysys is important. Here we will go
through the simple steps of adding a reaction and where they can be used. For this example the
methane combustion reaction will be entered into the system. We will assume no Temperature
dependence and 100 % conversion.
At the system parameters screen. Click on the ‘Reactions’ tab, an interface similar to the one below
in Figure 2-29 will appear.
B21 B23
R12 B22
B25 B24
From this screen it is possible to view reaction sets, components that are involved and associations
between fluids packages and reactions. To make life simple it is best to have appropriate names for
reactions and Groups of them.
Click on the ‘Add Rxn’ Button (B21) and a new window will appear, Figure 2-30 below, asking for
what type of reaction you wish to define. These are to be chosen based on the reaction data that is
currently available; for this example select ‘Conversion’, and click on ‘Add Reaction’. Another
new window will appear, this looks similar to the one shown in Figure 2-31 below. Define the
parameters listed in Table 2-19 below to complete the reaction parameters; to add in each
component click on the “**Add Comp**” cell and scroll down the list until the desired item is
highlighted and click on it.
Figure 2-30: The select Reaction Type window Figure 2-31: The Reaction Stoichiometry window
54
Table 2-19: The Reaction Parameters
Location Component Stoich Coeff Location Variable Value
Stoich. Tab Methane -1 Basis Tab Basis Component Methane
Oxygen -2 Co 100
Carbon Dioxide 1
Water 2
The reaction is now ready to use in a reactor/ tank or other accommodating vessel. Multiple
reactions may be added into Hysys and even over multiple Fluid systems (FP’s).
There are several Types of reactors in Hysys. These include PFR, and CSTR simulators. These are
useful for when the reaction kinetics or reaction rates are known.
Setting up a reactor in Hysys is straight forward. Start with a CSTR. It’s the vertical cylindrical
symbol with a line through it, located below the mixer on the toolbar. Enter the reaction set in the
‘Reactions’ tab. You can set the volume of the reactor on the ‘Rating’ tab. The reactor should then
solve.
NOTE: The CSTR and PFR will only handle rate type reactions (Simple Rate and Kinetic).
NOTE: It is also possible to size the reactor using the solving helpers like Adjust later on.
55
3 CHNG 2804 (Thermodynamics)
Thermodynamics is a key area where chemical engineers integrate their knowledge of the laws of
thermodynamics with real life applications. This section will help with the understanding that
Thermodynamics is used everywhere in chemical engineering and in day to day life. Hysys is a
good tool to use for thermodynamic problems; a few examples are shown below with a few extra
functional options for Hysys. Most of these examples will be based on the Power industry.
56
3.1 Thermodynamics Introduction
You have learned about Ideal gas properties in High School. Now is the time to start putting this
information in to practice by using it in a simulation environment, more realistic and complex gas
systems can then be attempted. Heat exchangers, reactors, pumps, compressors and valves are
simulated in Hysys; all of these will be used within this section. The following worked examples
will help develop your understanding of the thermodynamic capabilities of Hysys. In these
examples I will be showing quick information gathering techniques such as item tables.
Once this has been completed enter the simulation environment then the following steps may be
taken. Firstly you will notice a toolbar on the right of the screen. This is described above in the unit
operations section. Click on the Blue arrow. Then click somewhere on the blank workspace to place
the stream. Then Select the Compressor (Shown Above). Place this on the screen also. The
workspace should look similar to Figure 3-1 below.
From here double click on the Feed stream “1”. A window will pop open displaying the possible
inputs for the stream properties. We only need to fill in a few of these to remove the degrees of
freedom for the system so far.
The parameters that will be used to remove the degrees of freedom are listed in Table 3-2.
57
Figure 3-2 shows that the stream is now dark blue instead of light blue as above in Figure 3-1
New Colour
Figure 3-2: The stream changes colour to show the stream is ready
Next are the Compressor properties. From the worksheet screen double click on the compressor.
This should be coloured RED this means that it has not yet been specified. The following screen
should appear (Figure 3-3). The following information should be entered on this screen. From here
we will also be creating streams. These are the ‘Energy’ stream and ‘Outlet’ stream. This is
another way of creating streams apart from the menu. This is demonstrated in Figure 3-3 to Figure
3-8. Each figure will be described in detail below.
Figure 3-3 shows that there are drop down menus for each of the stream options so that it is easy to
find the one that is required. Hysys will only give you the option of using unconnected streams
here.
Figure 3-4 shows that it is also possible to create streams from these connection screens. In order to
do so just click in the connection name box and type in the stream name that is required, and Hysys
will automatically create a stream for you. Do the same for the Energy stream.
58
Figure 3-4: The filled out connections
Figure 3-5 shows what happens when you create streams from the compressor connections screen.
This is a much faster process than inputting the streams from the item toolbar. Notice that the
energy and flow streams are light colours and the compressor has a yellow outline. Now we need to
define either the compressors power capability or the outlet streams pressure. Figure 3-6 shows the
way to define the pressure from inside the stream properties screen. However this is not always the
best way to complete this task. In order to define the compressor completely and keep track of
errors it would be best to keep open the compressor window and define that property from in there.
This is demonstrated in Figure 3-7 and Figure 3-8 on the next page. There is no need to input a duty
number for any unit operation; it’s for Hysys to calculate, use another parameter such as pressure in
this case.
Figure 3-5: What the worksheet looks like now Figure 3-6: The outlet stream properties screen
Go To
Worksheet tab
to see adjacent
items
properties
59
Figure 3-8 shows only one parameter (Pressure) is required to complete the stream. This is because
the compressor has completed the rest of the calculations for you; this includes any assumptions
that have been made. For example Hysys assumes that the compressor operates at an adiabatic
efficiency of 75 % and the motor specifications have also been filled in. These assumed values are
RED. Figure 3-9 shows the calculated values after the parameter was entered. Make a note that the
temperature has risen by over 50 oC. This is a significant temperature increase.
Inlet Energy
Property
Outlet
60
COMPRESSION TUTORIAL
The previous example has covered simple single staged compression. The following example will
demonstrate staged compression with intermediate inter-cooling.
1. Assumptions:
Use an adiabatic efficiency of 100 % for this Question
a. A centrifugal air compressor takes 0.5 kg/hr of air at 22 oC to and 1 atm to 10 atm. What
would be the power requirement for a single stage compressor to achieve this?
b. If a two stage compressor with intermediate cooling back to 40 oC is used for the same
compression (1-10 atm), what is the minimum power (kW & hp) required assuming the
intermediate pressure is 3 atm?
c. Compare the power requirements of the part ‘a’ and ‘b’ and comment especially on the
two outlet temperatures.
d. Run a case study on the effects of the intermediate pressure (1.1-9.9 atm) on outlet
temperature. Discuss the trend and results, where they expected?
2. Repeat question 1 with an adiabatic efficiency of 75 %.
3. Carbon Dioxide is to be compressed from 1 bar, 25 oC to 5 bar.
a. Compare the work needed using a single reversible, adiabatic compressor to two-
stage compression with inter-cooling. The inter-stage pressure is 2.25 bar; inter-
cooling is to 40 oC.
b. What are the exit temperatures in both cases and why would they vary if at all?
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3.3 Item Tables
Item tables are a very useful way to view results on the workspace. They can remove the need to
continuously open up streams or operations data pages. This is useful for applications as initial
condition effect analysis or scoping for a specific result.
3.3.1 Viewing
Figure 3-10 shows how to access the tables on the workspace screen. This eliminates having to
open up each item to see what the values are. This is useful if you are constantly changing the
inputs and are trying to determine the effects. Figure 3-11 shows all of the available tables for this
example. There are a variety of different tables that show similar values. Some of these numbers
can be changed to different units such as the flowrate may be changed to mass flow units such as
kg/h.
To get these tables to appear right click on the object that you wish to view. Scroll down the list to
‘Show Table’ and select that option. The table should appear in the workspace.
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3.3.2 Modifying
In order to view different types of information available in Hysys in these tables a quick
modification step may take place. This is as follows:
• Right click on a table
• Select “View Properties”
• Click “Add Variable”
• Select the Variable you desire
• If there are any further specifications select the one you wish
• Click on “OK”
• From here you can name the selected item
• Close the window
These steps are illustrated in Figure 3-12 to Figure 3-14 below.
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3.4 Gas Expansion
Gas expansion is important to a chemical engineer in that this process is used extensively in
industry, mainly to generate electricity.
This example for using Hysys is only being used to allow for Hysys to mimic the Ideal Gas law
calculations, DO NOT USE THIS EXAMPLE AT ANY OTHER TIME!
For this example we are trying to find the change in volume associated with a pressure drop across
the expander under isothermal conditions. From the example above, (so we do not need to redefine
the system properties) open the compressor window and click the option box at the bottom right that
says ‘ignore’, this will no longer complete calculations or bring up all of the warnings associated
with this item.
Close that window then find the toolbar. Find the expander unit operation; this will look like a
backwards compressor. Add this to the screen and enter the following data found in Table 3-3.
We now need to see some results. For this we will need to modify the item tables.
Insert the “Actual Volume Flow” Variable to the table as above. This then allows for a quick view
of the volume change over the expander.
NOTE: This example is unrealistic and will not work in practice due to the fact that work is done
by the system, this means that heat will need to dissipate. It is impossible to build a perfectly
isothermal device due to the large surface area that would be required along with frictionless
parts. This application should never be used for design or scoping calculations in Hysys. Use the
Adiabatic Expansion example to give a better estimate.
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Table 3-5: The Required Data for the question
Unit Parameter Name Value
Worksheet Tab. Conditions Menu
S-101 Temperature 250 oC
Pressure 5 atm
Molar Flow 60 kg-mol/h
S-102 Pressure 1 atm
Now insert an expander onto the workspace and enter the relevant information into these forms.
These are listed below in Table 3-5 above.
The Expander should now solve. Have a look around at the options that are the set standards for the
expander. Changing some of these will give different circumstances, and solutions to the problem.
Final temperature should be 122.3 oC
TURBINE TUTORIAL
1. From the Expander defined above in Section 3.4.2, run a case study on the effects of
adiabatic efficiency (0-100 %) on the outlet temperature of the system.
2. Insert a second expander with an intermediate re-heater. Set the intermediate pressure to 4
atm, and the re-heater outlet temperature of 250 oC.
3. What is the effect on the outlet temperature (percentage difference) and power production
(sum of K-xxx) in comparison to part 1?
4. Run separate case studies of the intermediate pressure (1.5-4.5 atm) on inlet and
intermediate temperature (250-500 oC) while the inlet temperature is at 500 oC, on the Outlet
Temperature and Power production. Where the results expected? (i.e. do they match up with
hand calculated answers)
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3.5 Power Cycles
3.5.1 Single-Stage Steam Rankine Cycle
The steam cycle has been an important part of the power industry for over 100 years. To show how
to combine a complex system into Hysys, this section will take you through a step by step approach
to building a steam cycle in the simulator including parallel and series approaches to equipment
assembly. The basis for these examples may be found in Winnick 1997, Chapter 7 on pages 173-
177. For this example use Water and ASME steam as the system parameters.
One this has been completed you will see the fully defined Turbine above in Figure 3-15.
NOTE: See that the Vapour Fraction has been specified. This is because we want the limit for the
optimum efficiency.
NOTE: The intersecting stream has been labelled “2” This is because it is from another system
(utilities); this way it is easy to determine a secondary pathway.
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Table 3-7: The Parameters for the cooler
Item Parameter Value Units
E-100 (Connections) Tube Side Inlet S-101
Shell Side Inlet S-200
Tube Side Outlet S-104
Shell Side Outlet S-201
E-100 (Parameters) Tube Side Delta P 0 kPa
Shell Side Delta P 0 kPa
Heat Leak/Loss None
o
S-200 (Conditions) Temperature 22 C
Pressure 1 atm
S-200 (Compositions) Water 1
o
S-201 (Conditions) Temperature 30 C
S-104 (Conditions) Vapour Fraction 0
The vapour fraction is required in this example so as to specify that there is no vapour entering into
the next operation (the pump); this is the function of a condenser. The design of the condenser
should result in no vapour going into the pump with system disturbances taken into account. In
practice a set temperature of sub-cooling would be required to allow for disturbances in a real
system something along the lines of 5-10oC. To test this out set the temperature lower in this stream
after the cycle has been completed to see the effects.
Once this has been done the workspace should resemble Figure 3-16 below.
NOTE: That the work load for a pump is significantly lower than that of a compressor/ turbine
(~0.03). This is essential for the system to produce electricity.
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Figure 3-17: The pump added to the system
From here it is possible to rearrange the parts to make a cleaner representation of the cycle. Right
clicking on the items and rotating the parts from the ‘Transform’ menu will allow for a cleaner
representation such as the one in Figure 3-19 below. It does not matter if the loop is clockwise or
anti-clockwise.
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SINGLE-STAGE RANKINE CYCLE TUTORIAL
Run the following Case Studies of the following on Cooling water Flowrate (S-200) and Total
Power. Reset the original system settings before starting a different case.
• S-101 Temperature (120-400 oC) effects on the system.
• S-100 Temperature (450-650 oC) with S-101 Pressure set at (1 atm)
• S-100 Pressure (10-80 atm) with S-101 Pressure set at (1 atm)
• S-201 Temperature (25-50 oC)
• S-100 Pressure (10-80 atm) with S-101 Pressure set at (1 atm) on the effects of Temperature
in S-101 and Total Power
From here define the following parameters on parts as listed in Table 3-9 below.
The system should now be completely solved. Note down any major results on the parameters listed
below and comment on the differences to the single stage steam cycle.
• Total power out
• Cooling water flowrate
• Temperature in the stream before the condenser
• Total Heat required in the system (H-100+H-101)
• Efficiency: (Q-100+Q-101-Q-102)/(H-100+H-101)
69
An easy way to comment on the differences is to create a spreadsheet and do some simple
calculations on the Maximum Efficiency, Thermal Efficiency (Net energy out/Heat in) and outlet
Power. The easiest way to compare is to have both systems in the same workspace. Make sure the
variables heading in to the cooler are consistent for both systems.
The final view may look like Figure 3-21 below. I have labelled the single system as stream set 3.
To get the streams to have the colour scheme similar to that is shown below, change the scheme to
‘Temperature’ at (R12).
R12
Figure 3-21: The comparison Between Single and Multi Turbine Rankine Systems
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3.5.3 Brayton Gas Cycle
The Brayton Cycle is used by gas power stations. Air is compressed using some of the power from
the turbine. This uses the combustion off gases of a furnace. Set up a combustion reaction as
demonstrated in Section 2.8 above.
NOTE: Make sure you have Oxygen and Nitrogen, NOT Air as a component. Otherwise the
reaction won’t work properly.
Since the reaction is exothermic, the reaction rate is very hard to control.
The reaction is heavily favoured towards the products. The easiest way to
define this reaction is to assume a 100 % conversion.
NOTE: In reality there are side reactions such as Nitrogen and Sulfur
oxides creation with incomplete combustion creating CO as well. But we
are focussed on the temperature.
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Table 3-11 below has the specifications for the reactor that are required for this example.
3.5.3.4 Turbine
The pressurised combustion gases are expanded in the turbine. The turbine creates the electricity.
The parameters are listed below in Table 3-12.
Once this has been completed the Hysys workspace should look similar to Figure 3-23 below.
Initially the Combustion outlet temperatures (S-104) are excessive (2,109.4 oC). Most materials
cannot handle this kind of temperature range. This problem may be fixed by changing the flowrate
of air to extreme excess. Approximately 351 kgmol/hr is sufficient to reduce the outlet temperature
to a workable 1100 K which is below the safety limitations for most common steels.
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3.5.4 The Adjust Function
This feature is an alternate route for finding a specific set of conditions based
on a required specification which Hysys has to calculate to solve the problem.
I.e. Change a starting condition to solve for a specific temperature. The only
way to do this so far is trial and error and case studies; case studies are still
better to use for more complex systems. This allows for solving of a limitation
such as the outlet temperature to a combustion chamber to be calculated with
ease. The previous example will now be solved within reasonable parameters
to allow for material limitations. This can be done by back calculating with
iterations in Hysys. Find the Adjust function. The location on the toolbar is
shown on the right in Figure 3-24.
NOTE: The Adjust is located above the spreadsheet. Set the values listed in
Table 3-13 below.
Insert a heat exchanger operation. Have the low pressure exhaust gasses on the tube side of the
exchanger. One variable will need to be set; this will usually be the air outlet for the exchanger.
73
3.6 Hysys Steady State Controls (Set/Adjust/Recycle)
The adjust option was explored above in Section 3.5.4. In this section we will look into other
solving Helpers that Hysys has for us.
3.6.1 SET
This sets a variable of a stream to be the same or in a ratio to another one. For example if you have
2 flowrates that need to be solved simultaneously but you know that one is 3 times larger than the
other one. Insert the ‘Set’ Unit (S in a green diamond, right of the Adjust function)
Set the Target variable and the source of the solved variable.
On the ‘Parameters’ tab you can set the ratio of the two parameters with any offset.
3.6.2 RECYCLE
Like the Adjust function this is an iterative solver. (R in a green diamond, far right of the Adjust
function) Whenever there is a change in composition in a cycle this is to be used. Simply attach a
‘Recycle’ unit into a returning stream. Set an initial guess for the outlet of the recycle (usually the
other inlet) and let the solution come. Make sure the initial run solves before linking the recycled
stream back, and check that any inert material is mostly removed from the recycling stream.
NOTE: The recycle may not converge if there is complete recycle or an accumulation within the
circuit, i.e. recycling of an inert gas that is also in the feed stream, this system will need a purge
stream.
3.7.1 Refrigeration
Refrigeration is a complex process which has several considerations that need to be addressed
during the process of design. These include:
• Refrigerant selection • Safety
• Pressures • Flammability
• Temperatures • Toxicity
• Thermal expansion • Leakage direction
The general form of Refrigeration is:
• Evaporation – This process is where the refrigerant evaporates and takes in the energy from
the surroundings. (INSIDE)
• Superheat – This is to ensure that the refrigerant won’t condense in the compressor
• Compression – Compressing the gas to a higher pressure and temperature for condensation
• Condensation – This is where the refrigerant is cooled down using a cooler environment
than the one it is currently in.(OUTSIDE)
• Throttling/ Expansion – The now higher pressure fluid expands through a valve (capillary)
to the start of the cycle at much lower pressures. (cooling the fluid down further)
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3.7.1.1 Domestic Refrigeration
For this example we will try to mimic a domestic Refrigerator/Freezer.
This is a small application of the cycle described above. We will look for a refrigerant that performs
at below -18 oC in order to keep a freeze food. (Fisher&Paykel)
For the heat requirements in Hysys we will be assuming a temperature change range of
approximately 2 oC as the fluctuation range. We will also assume that there is fluid flow of around
‘1’ compartment volume (i.e. the whole volume is cycled past the coils) each minute. (This
assumption makes sense with a fan at the rear of the freezer and fridge)
For a Fridge there are several other parameters that need to be addressed.
1. The freezer has higher heat losses to the atmosphere because a freezer temperature of -20 to
-18 oC is quite low, this should mean that more heat is transferred into the refrigerant than in
the fridge section.
2. The fridge temperature is approximately 2-4 oC.
3. The heat outlet coils are cooled by air at atmospheric conditions (30 oC, 1 atm).
To define the problem we must set out the conditions for the system.
Insert 3 Heat Exchangers, 1 Compressor and 1 Valve. (For industrial systems the valve is usually
replaced with a turbine or expander to recover power losses)
There are several ‘utilities’ used in this cycle:
1. Freezer (S-FZx)
2. Fridge (S-FRx)
3. Atmosphere (S-ATMx)
In reality these Heat exchangers are not used. Fin exchangers are placed in the walls of the
refrigerator with insulation on one side. The Heat exchanger model only handles Shell and tube
exchangers which are not very good for simulating the Fin type or Plate heat exchangers. However
we will use them for an energy balance only since there is no need to use the sizing or heat transfer
data.
Add in the streams as shown below in Figure 3-25.
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Define the following parameters:
NOTE: You should use the adjust function to set the Temperature in S-102 to -6 oC by changing the
Vapour fraction of S-101.
This example is only to give a brief look at an application of refrigeration cycles. The information
for the data here is not realistic in that the vapour fraction in between the fridge and freezer would
never be set. This value would be highly dependent on the fluctuation in the temperatures in the
freezer compartment of the cycle.
The cold temperatures of the refrigerant are for Refrigeration of spoilable foodstuffs.
4
‘Handbook of Air conditioning and Refrigeration’, Second Edition, by Shan K. Wang, pg 9.8-9.11
Published by McGraw-Hill 2001
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3.7.2 Refrigerant Selection
There are several considerations that need to be taken into account for the selection of refrigerants4.
Other refrigerants may be found in Winnick et al. or from the ANSI/ASHRAE Standard 34-
Addenda 1992 or later. These sources are important for finding the correct refrigerant for a
particular system.
3.7.2.3 Toxicity
Due to the high pressures involved in the refrigeration systems the problem of leakage is evident4.
Since leakage is almost inevitable in older or more warn systems toxicity of the leaked gas is an
important consideration to take into account. Refrigerants need to be safe enough to use without
causing too much discomfort. In the ANSI/ASHRE Standard 34-1997, the toxicity of refrigerants is
classified as class A or B. Class A having very low toxicity in terms of exposure while class B have
exposure limitations.
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3.7.2.4 Flammability
In the ANSI/ASHRE Standard 34-1997 there are 3 classes of refrigerants in terms of flammability4.
NOTE: Safety Groups are classified as (Toxicity class letter), (Flammability class number). I.e.
Classification A2 has lower toxicity with a low flammability.
3.7.2.6 Inertness
Inert refrigerants are preferred due to the lower maintenance requirements for internal corrosion and
damage4.
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REFRIGERATION TUTORIAL
1. Define the following simple refrigeration cycle.
Remove the heat specification in Q1. Insert a spreadsheet function, have the import as Q1 Heat
flow. In the cell directly below the import enter the formula:
For the units that Q1 are in you will need to convert back to instead of the 12000
This is to work out how much ice at 0 oC we can make in tonnes per day.
2. What other sets of specifications would solve the system for an unlimited range of flows for the
refrigerator?
Remember any system limitations such as there is to be no liquid entering the compressor and that
overlapping temperatures (around the heater, water is flowing/freezing there) are not realistic.
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3.7.3 Air-Conditioning
To define the heating half of the system, simply copy the cooling system from above but have the
flow in the reverse direction. The parameters for both of the systems are listed below in Table 3-16.
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Table 3-16: The reverse cycle Air-Conditioning parameters4
Unit Parameter Value Units Unit Parameter Value Units
S-100 Temperature -20 oF S-203 Temperature -20 o
F
Composition 1 Composition 1
(R134a) (R-134a)
S-101 Temperature -10 oF S-202 Temperature -10 o
F
S-103 - S-201 -
S-104 Temperature 100 oF S-200 Temperature 100 o
F
Vapour Fraction 0 Vapour Fraction 0
S-INT~0 Temperature 24 oC S-INT~2 Temperature 24 o
C
Pressure 1 atm Pressure 1 atm
Flow 4 kg/hr Flow 4 kg/hr
Composition 1 Composition 1
(Air) (Air)
S-INT~1 Temperature 20 oC S-INT~3 Temperature 28 o
C
S-ATM0 Temperature 30 oC S-ATM2 Temperature 4 o
C
Pressure 1 atm Pressure 1 atm
Flow 5 kg/hr Flow 5 kg/hr
S-ATM1 - S-ATM3 -
K-100 Adiabatic 65 % K-200 Adiabatic 65 %
Efficiency Efficiency
VLV-100 - VLV-200 -
E-INT0 Delta P Shell 0 kPa E-INT1 Delta P Shell 0 kPa
Delta P Tube 0 kPa Delta P Tube 0 kPa
E-ATM0 Delta P Shell 0 kPa E-ATM1 Delta P Shell 0 kPa
Delta P Tube 0 kPa Delta P Tube 0 kPa
• Calculate the co-efficient of performance (COP). This may be done by using the following
ideas:
• 1kW used in the compressor will give how many kW of heating (heating efficiency) and
cooling (cooling efficiency).
Or
• COPcarnot= Tc/ (Th-Tc)
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4 Thermodynamic Package Choices
Selecting the correct Thermodynamics package is essential in Hysys. The wrong choice will lead to
erroneous results leading to poorly designed equipment or an entire design plan to be abandoned.
This section will guide the user through the right choice, or at least give and option of 2 or 3
packages that are suitable for each application. This section is to be used as a guide along with the
‘Fluids Package Wizard’. The following section has the different types of fluids packages in
categories with descriptions, this information may also be found in the Hysys help menus.
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4.1 Packages Introduction
Two of the key factors to consider for choosing a Fluids Package:
The basics of package choices, more information on operational conditions and functionality are
described below.
The equations of state (EoS) models, such as the Peng Robinson model, were developed originally
to deal with hydrocarbon gas systems. Although they have proven to be very reliable in predicting
properties of most hydrocarbon based fluids over a large range of operating conditions, their
application has been limited to primarily non-polar or slightly polar components. Polar or non-ideal
chemical systems have traditionally been handled using dual model approaches. In this approach, an
equation of state is used for predicting the vapour fugacity coefficients, (normally ideal gas
assumption or the RK, PR, or SRK equations of state), and an activity coefficient model is used for
the liquid phase.
However, whether an activity coefficient model can be used in a specific case depends heavily on
the pressure involved in your simulation. These models cannot be used in a generalized way or
extrapolating into untested operating conditions. Their tuning parameters should be fitted against a
representative sample of experimental data and their application should be limited to moderate
pressure. Consequently, more caution should be exercised when selecting these models for your
simulation.
If the operating pressure in your simulation is too high for activity coefficient models, an equation
of state method will become the only applicable approach. In the case that your system exhibits
some degree of non-ideality, you can consider using the modified PR model, called PRSV. With an
additional component dependent parameter and a more flexible mixing rule, this model has
extended the applicability of the original PR model to moderately non-ideal systems.
These are just some general guidelines in selecting property packages. More detailed information on
different property packages and their applicability’s can be found below.
NOTE: If there is only water, use the steam table packages. These and other specialty packages are
described in Section 4.3.5.
This decision tree is sufficient in most cases. However for the situations where it is of no help. The
Package wizard and the following explanations will solve the problem for you.
83
Figure 4-1: The Thermodynamics Package Decision Tree
84
4.3 Thermodynamic Packages
There are several Types of packages in Hysys. These include packages consisting of:
Each type of model fits different conditions. Within these categories there are basic fluids packages
and modified versions of some of these.
Base Packages:
• GCEoS
• Lee-Kessler Plocker
• Peng-Robinson
• SRK
• BWRS
• TST
This Type of Package is used in near ideal situations such as high pressure fluids (ideal gases are
assumed to have a large specific volume, the enthalpy of the fluid is assumed to be independent of
the density) or liquids, these packages are limited in functionality and the limits need to be
considered. The recommended starting packages are:
85
4.3.1.1 Generalized Cubic Equation of State (GCEoS)
Generalized Cubic Equation of State (GCEoS) is a fully customisable equation engine. If the
properties of each of the components are known and the models for these figures are not currently
in Hysys this model may be used to solve the problems.
For Oil, Gas, or Petrochemical applications, the PR EoS is the generally recommended property
package.
The SRK EoS should not be used for non-ideal chemicals such as alcohols, acids or other
components. These chemicals are more accurately handled by the Activity Models (highly non-
ideal) or the PRSV EoS (moderately non-ideal).
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4.3.1.7 PR-Twu
The PR-Twu property package is based on P-R and incorporates the Twu EoS Alpha function for
improved vapour pressure prediction of all HYSYS library components.
4.3.1.8 PRSV
The PRSV model extends the application of the original Peng-Robinson method for moderately
non-ideal systems. This EOS is shown to match vapour pressures curves of pure components and
mixtures more accurately than the PR method, especially at low vapour pressures. It is successfully
extended to handle non-ideal systems giving results as good as those obtained using excess Gibbs
energy functions like the Wilson, NRTL, or UNIQUAC equations.
The advantages of the PRSV equation are:
• It has the potential to more accurately predict the phase behaviour of hydrocarbon systems,
particularly for systems composed of dissimilar components.
• It can be extended to handle non-ideal systems with accuracies that rival traditional activity
coefficient models.
The only compromise for PRSV equation of state is the increased computational time and the
additional interaction parameter that is required for the equation.
The PRSV equations of state perform rigorous three-phase flash calculations for aqueous
systems containing H2O, CH3OH or glycols, as well as systems containing other hydrocarbons
or non-hydrocarbons in the second liquid phase.
4.3.1.9 Sour PR
The Sour PR model combines the Peng-Robinson equation of state and Wilson's API-Sour Model
for handling sour water systems and can be applied to sour water strippers, hydrotreater loops,
crude columns, or any process containing hydrocarbons, acid gases, and H2O.
In the Sour PR model, the K-values for the aqueous phase are calculated using Wilson's API-Sour
method. This option uses Wilson's model to account for the ionization of the H2S, CO2, and NH3
in the aqueous water phase.
NOTE: The flash calculation is much slower than the standard EOS because the method performs
an ion balance for each K-value calculation.
4.3.1.10 SRK-Twu
The Soave-Redlich-Kwong-Twu (SRK-Twu) property package is based on SRK property package
and incorporates the Twu EoS Alpha function for improved vapour pressure prediction of all
HYSYS library components. This package uses the SRK method to calculate VLE and the SRK or
Lee-Kesler method to calculate Enthalpy and Entropy.
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4.3.1.13 Zudkevitch Joffee (ZJ)
The Zudkevitch Joffee (ZJ) model is a modification of the Redlich Kwong equation of state. This
model has been enhanced for better prediction of vapour-liquid equilibria for hydrocarbon systems,
and systems containing Hydrogen. The major advantage of this model over the previous version of
the RK equation is the improved capability of predicting pure component equilibria, and the
simplification of the method for determining the required coefficients for the equation.
The Zudkevitch Joffee property package is generally used for High H2 Systems.
The recommended packages for the general conditions stated above are:
4.3.2.2 Wilson
The Wilson equation offers a thermodynamically consistent approach to predicting multi-
component behaviour from regressed binary equilibrium data.
However, the Wilson model cannot be used for systems with two liquid phases.
The Wilson equation gives similar results as the Margules and van Laar equations for weak non-
ideal systems, but consistently outperforms them for increasingly non-ideal systems.
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Unlike the van Laar equation, NRTL can be used for dilute systems and hydrocarbon-alcohol
mixtures, although it may not be as good for alcohol-hydrocarbon systems as the Wilson
equation.
NOTE: Due to the mathematical structure of the NRTL equation, it can produce erroneous multiple
miscibility (LLE) gaps.
4.3.2.4 Margules
The Margules model equation does not have any theoretical basis, but is useful for quick estimates
and data interpolation. HYSYS has an extended multi-component Margules equation.
NOTE: The equation should not be used for extrapolation beyond the range over which the energy
parameters are fitted.
4.3.2.5 UNIQUAC
The UNIversal QUAsi Chemical (UNIQUAC) equation is capable of representing LLE, VLE, and
VLLE with accuracy comparable to the NRTL equation, but without the need for a non-randomness
factor.
The UNIQUAC equation has a good representation of both VLE and LLE can be obtained for a
large range of non-electrolyte mixtures.
The UNIQUAC equation utilizes the concept of local composition as proposed by Wilson. Since the
primary concentration variable is a surface fraction as opposed to a mole fraction, it is applicable to
systems containing molecules of very different sizes and shape, such as polymer solutions. The
UNIQUAC equation can be applied to a wide range of mixtures containing H2O, alcohols, nitriles,
amines, esters, ketones, aldehydes, halogenated hydrocarbons, and hydrocarbons.
NOTE: Due to the empirical nature of the equation, caution should be exercised in analyzing multi-
component systems. It also has a tendency to predict two liquid phases when they do not exist. The
van Laar equation also performs poorly for dilute systems and cannot represent many common
systems, such as alcohol-hydrocarbon mixtures, with acceptable accuracy.
The van Laar equation has some advantages over the other activity models in that it can represent
limited miscibility as well as three phase equilibrium.
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4.3.3.1 Chao Seader (CS)
Use the Chao Seader (CS) method for heavy hydrocarbons.
The CS property package is used for the steam systems. The CS property package can also be used
for three-phase flashes, but is restricted to the use of pure H2O for the second liquid phase.
The CS method may be preferred in some instances. For example, CS is recommended for problems
containing mainly liquid or vapour H2O because the property package includes special correlations
that accurately represent the steam tables.
• Antoine
• Braun K10
• Esso Tabular
4.3.4.1 Antoine
The Antoine model is applicable for low pressure systems that behave ideally.
When using this method for super-critical components, it is recommended that the vapour pressure
coefficients be replaced with Henry's Law coefficients. Changing Vapour Pressure coefficients can
only be accomplished if your component is being installed as a Hypothetical.
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4.3.4.3 Esso Tabular
The Esso Tabular model employs a modification of the Maxwell-Bonnel vapour pressure model.
4.3.5 Miscellaneous
The Miscellaneous group contains Property Packages that are unique and do not fit into the groups
previously mentioned.
• MBWR • Amine Pkg
• ASME Stream • DBR Amine Package
• NBS Stream • OLI_Electrolyte
• Glycol PPkg
The BIP databank for the Glycol property package will be updated in future releases of HYSYS.
Currently, there may be some limitations or missing BIP for certain component pairs. For example,
heavy hydrocarbons or hypothetical components which may not have any interaction parameters
available.
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option with HYSYS giving you access to a proven third party property package for reliable amine
plant simulation, while maintaining the ability to use HYSYS' powerful flow sheeting capabilities.
The amines property package is fitted to extensive experimental data gathered from a combination
of D.B. Robinson's in-house data, several unpublished sources, and numerous technical references.
The Amines method does not allow any hypotheticals.
The absorption of H2S and CO2 by aqueous alkanolamine solutions involves exothermic reactions.
The heat effects are an important factor in amine treating processes and are properly taken into
account in the amines property package.
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4.4 Bad Thermodynamic Package Examples
The following examples are to illustrate the undesired effects of poor Thermodynamic Package
choices. Any major problems will be given at the end of each example. These examples are to
reinforce the knowledge that each package is not designed for all conditions or materials. Major
problems that can occur are three and four phase theory limitations such as the prediction of an
oleic phase in water/ethanol systems, un-realistic liquids such as in the first example below and ice
formation is not predicted. There are many other predictive problems.
From here define the following system described in Table 4-1 below; be careful not to define the
outlet streams. The outlet streams are where the problems will occur.
Define the Fluids Package as UNIQUAC.
Notice any major problems with the reactor temperature or exiting streams (S-101, N-100).
Now change the package to one that works for these conditions (use the Wizard).
The actual reactor temperature for this example should be around 2126 oC and there should be no
liquid flows. (Hence the N-XXX stream name)
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• Firstly have the fluids package as ‘Wilson-ideal’.
Note down any errors that occur. (BIP’s non-existent)
Note down what you notice to be incorrect. (Compare to Table 4-3 below)
• Then try ‘NRTL-ideal’
Note down any errors that occur. (BIP’s non-existent)
Note down what you notice to be incorrect. (Compare to Table 4-3 below)
• Then try ‘Antoine’
Note down any errors that occur.
Note down what you notice to be incorrect. (Compare to Table 4-3 below) (Only water in
the Aqueous phase)
• Then try ‘LKP’
Note down any errors that occur.
Note down what you notice to be incorrect. (Compare to Table 4-3 below) (No 3rd (aqueous)
phase detected)
• Then try ‘PR’
Note down any errors that occur. (Components not recommended-Ethanol)
Note down what you notice to be incorrect. (Compare to Table 4-3 below)
The actual answer for the correctly defined system is shown in Table 4-3 below.
Table 4-3: The Correct result for the problem above (Found using PRSV)*
Mol Fraction S-100 S-101 S-102 S-103
Ethanol 0.2 0.0274 0.1374 0.2966
Water 0.2 0.0105 0.0004 0.3665
Methanol 0.2 0.0568 0.0202 0.3366
Methane 0.2 0.0015 0.9403 0.0003
n-Decane 0.2 0.8009 0.0015 0.0000
Total (L/min) 1.0 0.1547 0.5686 0.2767
*Similar results were found using TST, PR-Twu and SRK-Twu.
Why was PRSV chosen for this example as the correct answer, what other packages are fine to use?
Refer to the package descriptions section above.
NOTE: In general never ignore a warning as you enter the ‘simulation basis’; However for the
purposes of this example we will.
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5 CHNG 2806 (Analysis Practice 2)
The subject material within this section is for the purposes of expanding the use of Hysys for
projects and laboratory simulation and the understanding of a greater amount of major operational
equipment that are used in industry.
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5.1 Additional 2nd Year Hysys Unit Operations
Basic separation equipment and peripheral systems are important in design and analysis of systems.
In this section we will be looking at cooling water systems, and separation methods. All on a level
of understanding that should be known by this stage in the course.
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5.3 Basic Distillation Concepts (Component Splitter)
This is a useful unit operation to have in a preliminary process flow sheet. This is
due to the simplification to the distillation process while giving valued
information that can be used for the later processes. For example while dealing
with new distillation system design the component splitter is used to determine
the system pressure that needs to be used for distillation columns and other
separation devices this is because it gives a reasonable estimate for the mass and
energy balances, this is based on the cooling/heating requirements. For example
the limit of 60oC in the overhead so that the cooling water will not go above 50oC
when it enters the cooling tower. This is done primarily using a case study of
Pressure on outlet temperatures. This operation may be found in the distillation
section of the toolbar. The component splitter is the grey operation on the right of Figure 5-1:
the top row of this section of the toolbar, marked with an ‘X’ within the symbol. The Location
of the
Component
This is an over simplified version of a separation operation. However, this has its
splitter
advantages in that it can loosely simulate operations such as distillation,
molecular sieves and membrane facilities. It is good for flowsheeting for mass
balances over a separation system. Take these factors into consideration when using this operation.
Since this is relatively complex in comparison to the separators that have been used up till now, we
will do an example together to help our understanding of the systems and defined variables that are
available.
NOTE: The distillation section of the toolbar is found below the unit operation section. The
columns look like ‘E’s.
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SEPARATION WORKSHOP
Set up the system with Water, Ethanol as the components. Set the Fluids package to PRSV or
UNIQUAC. Insert a component splitter into the workspace. Add in the streams and no energy
stream for this application.
For the inlet conditions it is usually set that the temperature is slightly above that of a saturated
liquid (i.e. set the vapour phase fraction to zero, 0, or just above it 0.05). Initially set the pressure to
1 atm, 2 kg/min and the inlet composition to 20 % ethanol, 80 % water.
The splitter will now need to know the required splits for the system. These can be entered in the
‘Design’ tab, ‘Splits’ menu. Set the splits to 99 % ethanol and 5 % water in the overhead outlet.
The other stream will solve.
REMEMBER: Splits are not compositions; they are more of a recovery than a concentration.
NOTE: Setting the splits to 100 % is possible in Hysys but this is highly unrealistic for most
applications. It is possible to violate azeotropes using the component splitter; this is because the
splitter can simulate complex separations such as molecular sieves in separation efficiency;
however with that operation the temperature is not as important.
After this Hysys will ask for an ‘Overhead Pressure’ this may be solved in a variety of ways, all of
which may be completed from the ‘Design’ tab, ‘Parameters’ menu.
In this menu there are several options available to change the solving method for the splitter, these
are:
1) ‘Use Stream Pressure Specifications’, (P) this is the default selection.
(all pressures will need to be defined here)
2) ‘Equalise all Stream Pressures’, (P) this is to be used if there is no pressure drop through the
system (useful for atmospheric columns)
(Only one pressure specification will need to be defined [Feed] and at least 1 outlet
condition)
3) ‘Use Stream Flash Specifications’, (T) this is the default selection. At least one temperature
must be defined.
4) ‘Set lowest feed pressure for all product streams (equalise in Dynamics mode)’, (P) this is
the same as ‘2)’ for all of our applications. (This mode is not recommended for use at any
time, it is difficult and beyond the scope of any of our work)
5) ‘Calculate Equal Temperatures’, (T) this option sets the temperatures of the outlets as the
same. (This mode is not recommended for use at any time because it is unrealistic)
For this example we will define no pressure change (option 2) and a no vapour out of the Bottoms
(Vapour fraction = 0).
Perform a mass balance over the Splitter to mimic the results.
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SEPARATION TUTORIAL
1. Effect of Pressure
a. Run a case study on the effects of pressure (0.1-3.1 atm) on a water-ethanol system
described in the worked example above.
b. When does the overhead stream temperature drop below 60 oC and when does the
bottoms stream temperature go above 110 oC?
2. Determine the effect of changing the feed composition (Ethanol 0.05, 0.2, 0.4, 0.6, 0.8, 0.95 mol
fraction) on the system used in Question 1. Set the pressure at 1 atm. What do you notice about the
temperature ranges?
NOTE: You will not be able to run a case study on this which means that the composition will need
to be changed each time.
NOTE: Calculating the flow and tube length limits are essential in later design, this is because
Hysys will not help you size the system. The ACOL design will if the licence is installed and the
application added.
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6 Introduction to 3rd yr
6.1 More Unit operations
6.1.1 General Reactors
This set of Reactors (Conversion/Gibbs/Equilibrium/Yield Shift) shown in
the sub toolbar on the right of the main toolbar are important for Reactor
design and reaction completion calculations based on the different types of
Reactions.
6.1.2 PFR
This simulates a PFR and is located to the left of the General Reactors
button. (The button that looks like a pipe with mesh in the middle of it)
This reactor is best to be used after a general reactor has been used and
defined. This reactor is good for mass balances and reactor sizing. This type
of reactor can only handle rate type reactions.
6.1.3 CSTR
This is located to the left (far left) of the PFR button. This looks like a tank Figure 6-1: The
location of the
with a stirrer in it. This reactor simulates a CSTR and is best to be used after reactors toolbar
a general reactor has been used and defined. This reactor is good for mass
balances and reactor sizing. This type of reactor can only handle rate type
reactions.
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6.1.5 Sub-Flowsheet
The sub Flowsheet is for neatening up Complex Process Flowsheets and
linking group-work together. Simply add in a Sub-flowsheet, from here you
can import a sub flowsheet, start blank of copy cut items into the sheet.
Simply set up the links between the sub and the parent flowsheet in the
interface.
Click on ‘Sub-Flowsheet Environment’ to enter the flowsheet.
The Location of the Sub-Flowsheet is shown on the right.
6.1.6 Solid-Operations
Just be aware of these mainly for second semester and for 4th year. Figure 6-3: The
The Fluids package is only important for the solids interaction to the Location of the
Sub-Flowsheet
transportation fluid.
The location of the Solid Operations Sub-Toolbar is shown right.
Within this Toolbar are several Solids Processing Tools. These include:
The PID controller is the only type that will be shown in the following
examples.
Figure 6-5: The
(GREEN CIRCLE WITH 1 line through it, the middle option on the sub-
location of the control
toolbar). toolbar
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6.2 Components Filters
This is an essential function when dealing with special types of materials (components).
When you are at the component selection screen, click on the ‘View Filters’
button, located to the right (Figure 6-6) of the ‘search’, this will bring up the
window shown on the right.
You will notice the option to select either the fluids package filter (top) or the
Family filter (bottom) options. The property package filters are to be used for
the exclusive component packages such as BWRS. Using the family filter is
very useful for applications such as this, solids operations.
You will notice the components list gets filtered and sorted through the filter
and now only the solid materials are left. These include:
NOTE: To remove the filters just click on the ‘Use Filter’ button again.
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7 CHNG 3801 (Reaction Engineering)
Reaction engineering is important for all chemical engineering. The design of small and large scale
reactors including reactor choice is essential for an efficient process design and manufacturing
process.
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7.1 Reaction Engineering Introduction
In Hysys there are several types of general reactor that has been programmed for specific reaction
definitions. There are also general reactors that can be designed to a greater extent such as tube
packing in the PFR. The major way to set up these reactors is to start with the reactor type to match
your reaction definition. From here it is possible to select workable flows and determine the effects
of the reaction on the system.
Hysys assumes that some reaction types can be controlled and the reaction temperature effects need
to be determined for Hysys to determine the inhibitive reactor conditions. Further information will
be found below in the relevant sections.
• Conversion
• Equilibrium
• Heterogeneous Catalyst
• Kinetic
• Simple Rate
7.1.1.1 Conversion
The conversion reaction may be defined using the components stoichiometric co-efficients and a
basis. The basis is a reactant component that is the basis of the conversion. A simple temperature
dependant equation may be used given the stoichiometric co-efficients and the reaction phase, if
unsure of the reaction phase properties select overall.
7.1.1.2 Equilibrium
After the stoichiometry has been entered the equilibrium reaction rates may be defined in a variety
of ways. Set the basis to the desired setting (Activity or a concentration), the phase should be set as
either liquid or vapour phase. The temperature limitations for the reaction may also be entered if
they are available. Set the Basis units if a concentration has been selected. ‘Keq Source’ (Radio
button section on the right of the basis information) is the equation type for the ‘Equilibrium K’
source. The preview of the selected K values/Equations may be seen in the ‘Keq’ tab. A
temperature approach may also be entered in the ‘Approach’ tab.
Most of the time Algebra will need to be completed first and some assumptions such as pressure
independence will need to be made to get the rate law co-efficients in the right form.
NOTE: Some reactions have been pre-defined. These may be found on the library tab of the
Equilibrium Reactions option only.
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7.1.1.3 Kinetic
After adding in the stoichiometry the Basis (same as Equilibrium) the reaction rates in both
directions (forward and Reverse) may be entered in the ‘Parameters’ tab. Keep the format the same
as in the Equation Help zone (extended Arrhenius Equation) to the right of the co-efficient input
tables.
On the ‘Denominator’ tab of the Heterogeneous Catalytic Reaction property view specify a value
for the co-efficient ‘A’ and activation energy ‘E’ in the column of the Component Exponent table.
This value is used in determining the adsorption term (K).
In the remaining columns specify the exponents of the absorbed components.
In the Denominator Exponent field specify the overall exponent term n.
The Screenshot below (Figure 7-1) may be accessed by clicking on the ‘Kinetics Help’ button at
the base of the window.
This reaction is of Rate Type.
Where :
fx (basis) = The functions of basis, the product of ' Concentration' to specified exponents
The indexes (1, 2 , ...i) in the constants K , A and E indicate the matrix location
n is the denominator exponent
Figure 7-1: The Catalytic Reaction Kinetics basic setup
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7.1.2 Reactor types
There are several types of reactors that are contained within the Hysys library. For more complex
systems it is possible to have reactions in distillation column trays or tanks/separators. This is not to
be done at any stage, reactions are best left to reactors; operation extensions may be simulated
around the reactor later.
7.1.2.1 PFR
A Plug Flow Reactor (PFR) is essentially a pipe with the reaction progressing along the length of
the reactor. At steady state the reaction completion is defined using the Volume/Length of the
reactor. Several extra parameters are required for this unit to solve for the volume, length, diameter
etc.
7.1.2.2 CSTR
A Constantly Stirred Tank Reactor (CSTR) is a tank with a stirrer for mixing the reactants. Several
extra parameters are required for this unit to solve for the volume, stir rate etc.
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7.2 Harder Distillation
To explain distillation an example is best used to illustrate the complexity of the process. For this
example we will be using the binary system of Benzene and Chloro-Benzene.
Table 7-1: The Overall mass balance for the binary distillation column
Inlet Tops Bottoms
Molar Flow (kg-mol/h) 160
Benzene (mol fraction) 0.55 0.95 0.10
Chloro-Benzene (mol fraction) 0.45 0.05 0.90
Pressure (atm) 1 1 1
Vapour/ Phase Fraction 0
• Open a new worksheet in Hysys and add the components Benzene and Chloro-Benzene.
Choose the fluid package (PRSV this is the package we will be using in Hysys) and then
enter the simulation environment.
• Create a material stream and set the vapour fraction to zero (0), i.e. a saturated liquid. Set
the pressure to 1 atm, a flow of 1 kg-mol/hr and the composition of benzene to 0.05 mole
fraction. We use benzene as it is the lighter key in this system.
• Open the composition window of the stream and note the liquid and vapour phase fractions
of benzene. Change the mole fraction of benzene from 0.05-0.95 in steps of 0.05 and note
down the vapour and liquid fractions for each condition. This is the equilibrium data for the
Benzene/ Chloro-Benzene system.
• α can be calculated from the obtained liquid and vapour fractions of benzene using Equation
7-1 below. Check that they are relatively constant. This data assumes constant volatility, for
this system is acceptable. i.e. ONLY IF α is approximately constant the formula below can
be used.
• Now conduct tray by tray calculations using the constant relative volatility value obtained
from above, a reflux of 2.40 and the procedure found in Section 7.2.1.2. Determine the
number of stages and composition of benzene vapour and liquid on each stage.
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7.2.1.2 Tray by Tray Calculations
To model a distillation column we need to model an individual plate. Under steady state conditions,
this involves simultaneously solving an overall mass balance, component balances (i.e. one less
than the overall number of components), an energy balance, and any appropriate VLE relationships.
This is generally a simple task that can be completed iteratively for several conditions by hand or by
enlisting the fast processing speed of computers, usually using spreadsheets or simulators such as
Hysys.
Vn-1 Ln-2
Equation 7-2: The Equations used to solve for tray
Yn-1 Xn-2
Stage “n- by tray calculations
(1) L n −1 = L n = L
Vn Ln-1 (2) Vn +1 = Vn = V
Yn Xn-1
Stage “n” (3) Vn +1 y n +1 + L n -1 x n -1 = Vn y n + L n x n
Vn+1 Ln α xn
(4) y n =
Yn+1 Xn 1 + (α - 1) x n
Stage “n+1”
Where: ‘n’ is the tray number
Figure 7-2: A simplified representation of a part of
a tray system
Open a new worksheet in Hysys and add the components Benzene and Chloro-Benzene. Choose the
fluid package (PRSV) and then enter the simulation environment. (Or open the one from the
previous section where you worked out the VLE of the system)
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Insert a short-cut distillation column. The location of this is shown on the right (Figure 6-2). The
short-cut method column is the one in the second row on the right (grey with column lines), just
under the splitter. Use the same specifications as outlined in the notes:
A minimum reflux ratio will be calculated by Hysys. Check that it is close to the minimum reflux
ratio you previously calculated by hand. Using 1.5x Rmin, input an external reflux ratio into the
shortcut column.
Hysys should now calculate Nmin, Nactual and feed position (located on the Performance tab). Note
these values and then change the feed to a saturated liquid and again note the differences.
These figures are only to be used as a guide.
NOTE: To get the actual configuration that is required you will need to define the component
recoveries in the rigorous method and return the actual reflux ratio to the short cut until the
rigorous and short cut both close to each other. This will then leave the difference in specification
effects to a minimum.
Step 1: Name and define all of the material and energy streams. Select the type of condenser
required. Set the number of stages and the feed stage for the column.
NOTE: You can define the streams to be exactly the same by clicking on the ‘Define from Other
Stream…’ Button located at the base of the stream properties window (below the tabs). A new
window will pop up with options such as what values you wish to duplicate.
Step 2: Set the pressure of the condenser and re-boiler. This can be approximated as the same
pressure as your feed stream.
Step 3: Ignore all the side-ops and click next. The side ops are used for pumping and piping
requirements, extra condensers/re-boilers and other useful modifications to a column. The level
controllers show up here when you enter Dynamic mode.
Step 4: Set the reflux ratio to that noted down from the short-cut model. (~2.4)
You must now define the some specifications in the column to remove the degrees of freedom.
These are generally the requested recoveries of the components.
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7.2.3.1 Adding Column Specifications
Go to the monitor option on the design sidebar and then click on the ‘Add Spec..’ button.
A number of specifications can be defined but the most common one is the reflux ratio (which is a
Hysys default) and the Column Component Recoveries. The reflux ratio should be already set
leaving 1 more degree of freedom, of which we will use the component recovery. Set the Draw as
your distillate stream, the spec value as 0.9 (given in notes) and the component as benzene. Back in
the monitor window tick this new specification as active and then run the column. This should
produce a converged column.
Experimenting with the degrees of freedom, by changing the components or streams allows for a
more dynamic approach to column design.
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8 CHNG 3802 (Process Control)
Process control is an important concept that helps with safety systems and profitability. Process
control involves Dynamic response reduction, overshoot removal and system stability analysis.
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8.1 Linking Drive shafts
This is important for any multi-stage system or multiple rotational equipment designed in-line. To
link the drive shafts, simply go to the ‘Design’ tab, ‘Links’ menu. Set the links from start to end.
Only fill in the next link and the gear ratio.
NOTE: A gear ratio of 3 means the next link runs at 3 times the speed of the current item.
Due to the complex mathematics involved in dynamic simulations, most of the operations in Hysys
are not simulated in Dynamic mode. The following examples are simple enough to cause major
problems if they are not defined carefully.
In this section there are a few examples of dynamic specifications on some of the operations
explained in detail above. There is even a section on how to set up a dynamic controller in Hysys.
Other unit operations are able to be used in Hysys including some of the rate type reactors and even
distillation columns (extremely hard to setup).
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8.2.2 Location of the Dynamics Specifications Tabs
On every unit that is able to be run in dynamic mode there is a tab that allows for parameter setting
and some operations have dynamic correlations or heat transfer correlations that are not available in
Steady State mode. These tabs are usually located at the far right of the tabs lists.
Each operation will have a different Dynamics interface. A few of these are shown below in the
descriptions.
Flow rates should only be determined by pressure differences or by equipment such as pumps and
compressors/ expanders.
The assistant may select flow specifications for simple feed streams instead of adding equipment to
keep the case simple.
Valves should be inserted in the lines where flow needs to be specified to determine the flow and
pressure in the system. This is also true for real life situations.
Terminal streams connected to equipment with pressure flow (flow proportional to pressure
difference) capability get pressure specifications, otherwise a valve is inserted.
The natural “flow proportional to pressure drop” relationship needs to be activated for these items.
8.2.2.3 Tanks
The tank units can simulate fluid hold-up, level fluctuations, heat loss (heat exchanger menu) using
heat exchanger sizing, pressure drops over the tanks and even add in a Level Controller. In order to
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set up the initial setting for dynamics mode simply size the tank. 2 m3 is usually assumed for the
tank size. This menu is displayed below in Figure 8-2.
The Dynamic specification for Vessel Pressure is usually not set here but by the pressure drop into
and out of the tank with the inlet pressure set by either a pressure device such as a pump,
compressor, expander
or pipe etc.
To add in a Level Controller simply click on the ‘Add/Configure Level Controller’ Button.
Due to the nature of natural flow Hysys assumes that the flow is proportional to the Pressure.
The K value is the ratio of mass Flowrate to a function of Pressure and mass Density.
The natural “flow proportional to pressure drop” relationship needs to be activated for these items.
Each of these types of items must have either its pressure drop or a pressure flow ability enabled.
The pressure drop option should not be used because this is physically unrealistic.
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Material flow is driven by pressure differences and resistances, the change in flowrate stops when
the pressures have been equalized. A fixed pressure drop specification does not allow for this
natural process.
8.2.2.6 Valves
The valve really is an important unit in Dynamics mode. These are used as the controllers of flow
and pressure. Almost all of the control loops utilise a valve as a counter disturbance device.
Firstly the Valve needs to be sized. Do this in steady state mode before entering Dynamics, sizing
the valve may be completed in the ‘Rating’ tab of the valve, as shown in Figure 8-5 below. The
Valve Characteristics (Section 2.2.3) may also be set here.
Figure 8-5: The Sizing options for a valve. Left is the Universal Gas Sizing Parameters and on the right is the
Simple Resistance Equation Parameters
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Next the Dynamic specifications need to be set. This may be done on the ‘Dynamics’ Tab shown
below in Figure 8-6. In this section you can simulate the surrounding pipe, the manual actuator
specifications and flow limitations. (These are in the different menus)
If a valve has not been sized, click on one of the Size Valve buttons on either the ‘Rating’, ‘Sizing’
menu or the ‘Dynamics’, ‘Specs’ menu.
NOTE: A pressure drop and a flow must be present for the valve to be sized.
8.2.2.7 Pipe
This operation changes quite a bit in Dynamics mode. Firstly the pipes duty is not calculated in
Dynamics mode. The heat loss correlations are replaced with simplified heat transfer/loss
calculations. There are 3 modes for heat loss calculations.
• None
• Simple- this involves a calculation based on the feed. Using only the Q=UA∆T
• Detailed- this includes temperature profiles through the pipe walls
o Included are the wall Conduction /Insulation
o Included are the convection Calculations
There is no need to go to the dynamics Tab in the pipe segment unless a Pipe Flow model is to be
selected. These are located on the ‘Design’, ‘Parameters’ menu.
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8.3 Entering Dynamic Mode
In order to enter Dynamics Mode, click on the wavy red and blue line object in the Hysys toolbar
(to the left of the basis environment button) as shown in Figure 8-8 below. Once the button has been
pressed either one of two dialogue boxes will appear.
One saying “Are you sure you want to switch to dynamics?” which means that everything is ready,
or “The dynamics assistant identified items which need attention. Would you like to resolve these
first and not run the dynamics?” which means that some of the specifications have been made
incorrectly and need to be either changed or modified.
Figure 8-8: The location of the Dynamics Mode and steady state mode buttons
This function is very vast and complicated. If there are any modifications/errors that are not
understood browse the Tabs and menus until the same one is listed. (There are very specific tables
and lists.) Simply click on the ‘Tell me why…’ button located on the bottom right of the window.
This gives a good description of the general problem and possible solutions, including the one
Hysys will use as a default.
UTILISE THIS RESOURCE AT ALL TIMES IN DYNAMICS and for setting up for
Dynamics Mode.
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8.3.2 Strip charts
In all of the dynamics tabs (except on the energy stream) there is a menu option that is a strip chart.
These are similar to the case study graphs but are updated on a time scale.
To set up a simple strip chart, go to the strip chart menu and make a selection of predefined strip
charts from the dropdown menu. (Usually small dynamics is plenty) Remove the unnecessary
specifications such as volume (if that is not being calculated or changed).
For more complex strip charts, or customised ones over an entire system, go to the data book
window (the one with the case studies
setup). Enter the data that you wish to
view in the strip chart within the
‘Variables’ tab, as with the case studies.
Figure 8-9 on the right shows the layout Figure 8-9: The Strip Charts tab of the DataBook
of the ‘Strip Charts’ tab.
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8.4 Simple Dynamic Examples
The following 2 examples are simple applications of the dynamics engine.
A simple gravity drained tank. This application will utilise the Spreadsheet function as the tank
operation does not have a gravity model set in.
NOTE: If there is a major problem with the model. Return to steady state mode; redefine the
problem and start-up dynamics again.
To set up the dynamic tank, use Air and Water in a 1:1 ratio as the components and Peng Robinson
as the package; insert a tank and a spreadsheet into the workspace.
The next step is to use the spreadsheet to have the flowrate out calculated and sent to stream S-102.
Open the spreadsheet and have an import of V-100 (Aqueous or Liquid Level); this is the liquid
height in the tank.
Select an export or S-102 (Std. Liq. Vol. Flow Spec); this is the dynamic specified Volume flow.
Click the ignore check box in the bottom right of the spreadsheet window. This is to remove any
steady state conflicts that will occur.
Open a strip chart with the tank level, pressure and molar flowrate and temperature. Click play and
watch the effects of the system.
NOTE: If you click ‘Yes’ the assistant will open and you will see that it does not want the
spreadsheet to be ignored.
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8.5 Controllers
There are several types of controllers catered by Hysys,
however we will only be using the ‘PID controller’
function; this is the most generic type of controller, the
‘Connections’ tab is shown on the right in Figure 8-10.
Once inserted the controller is a generalised IC controller. However once the PV and OP have been
entered the type of controller will change to:
• LIC for level control
• PIC for pressure control
• FIC for flow control
• TIC for temperature control
• XIC for concentration control
In this menu you can enter the controller Figure 8-11: The LIC Parameters, Configuration Menu
tuning parameters, set point, operational modes and the PV range.
Other menus in the Parameters tab may be used for advanced tuning, signal disturbances etc.
To view a convenient interface with the SP, PV and OP points click on the ‘Face Plate’ button
located at the base of the window.
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8.5.2.1 Using C-Station
Before the controller is added (or when it is turned off) create a disturbance in the system (like the
inlet flowrate) and collect the data using the Strip chart.
NOTE: Using the Databook Strip Charts tab click on the ‘Historical’ Button to open up a table
with all of the data in the stripchart.
Copy the data (This may be done by highlighting the data and using the copy shortcut ‘Ctrl+C’) to
a text file and save the file.
Open the file in C-Station and use the tuning tools to gather the tuning parameters.
8.5.2.2 Auto-Tuner
If the controller is inserted, the ability to automatically tune the controller is available. To do this
make sure the system is in a steady state and the system is within its stable range.
• Go to the ‘Parameters’ tab, ‘Autotuner’ menu. Figure 8-12 below shows this view.
• Set the amplitude (1 % is fine) as the step change as a percentage of the current value
• Click on the ‘Start Autotuner’ button
• Once the process has been completed (this should only take a few seconds) the bottom table
on the screen will be filled out.
• Click ‘Accept’ to accept the new tuning parameters
NOTE: If the autotuner does not start the system is not steady. To check this, turn the controller to
manual and find a steady state solution first. Turn the controller back on after the tuning has been
completed.
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8.6 Controller Examples
The following are simple controller examples.
The gravity drained tank from the above examples sets a new level of complication to the standard
control loops that will be explored in the tank. These examples are linear extensions of the previous
examples and should be attempted in order.
All of these examples are to be run with Air and Water as the components and Peng-Robinson as
the Fluids Package.
The Valve will now need to be sized. Set the outlet pressure at 0.8 atm so there is a pressure drop
through the valve.
Click Size valve in the Dynamics Tab. The size should be Cv= 2.00 USGPM @ 50 % open.
Double click on the tank to open up the Tank window and go to the Dynamics tab.
To insert a Pre-defined Level controller, click on the ‘Add/Configure Level Controller’ button
near the bottom of the window. Close this window and open up the controller.
The controller is already defined for you. Unfortunately this is not a very good configuration and
should be modified to a faster acting set of Tuning Parameters. Both of these sets of parameters are
shown in Table 8-1 below.
Add the Face Plate and set up a Strip Chart for the Tank (Level, Temperature, Pressure and Liquid
Outlet Flow). Then open up the feed stream window (S-100) then minimise the worksheet.
Change to Dynamic mode; then rearrange the new interface of tables, charts and faceplates will help
in viewing the responses. This should look similar to Figure 8-14 below. Larger Strip charts are
easier to see.
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Figure 8-14: My view for monitoring response
Change the flowrate in to the tank and view the effects on the system. You can also change the set
points using the face plates.
Now go to the ‘Parameters’ tab ‘Configuration’ menu. Set the following control parameters.
First Guess
Kc 0.01
Ti 1 minute
Setting up the same interface now with an extra face plate is required to see the effects of this new
system.
Change the Flowrate of the Inlet or change the set points using the face plates to see the effects on
the system.
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8.6.1.3 Tank (Gravity Drained) with Pressure and Level Controller
It is possible to integrate a gravity response into the system. Set up the spreadsheet with the flowrate
of S-104 instead of the immediate outlet of the tank.
Switch to dynamics mode and ignore any warnings, Do not use the assistant, Hysys is quite
sensitive in what can be defined. Set up the strip charts and start the solver. Ignore any pressure
warnings, the system corrects itself.
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9 CHNG3806 (Products and Value Chains)
In Chemical Engineering solids operations are very important, from pharmaceuticals to waste water
treatment to mining and beyond. Solid separation from a solvent or even gas cleaning is used in
everyday processes such as air conditioning or vacuum cleaners. This section will introduce the
solids processing on an industrial scale, from cyclones to rotary filters.
For all of these examples Carbon, Water and Air in Peng-Robinson will be used.
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9.1 Stream Properties
In all of the streams that contain a solid
component (the composition needs to be defined
first) you will notice a new menu option in the
worksheet tab, ‘PSD property’, PSD stands for
(Particle Size Distribution). This menu is shown
on the right in Figure 9-1 with carbon specified in
the ‘Composition’ menu as 0.2 mol fraction with
air. In this menu you can define the Particle size
distribution and an equation of best fit type model.
This is useful if the particle sizes or distributions
are known, or a range of particle sizes with an Figure 9-1: The PSD Property menu screen
assumed probability density.
NOTE: If the PSD Property menu option is not available to you make sure the solid material has
been defined in the composition menu.
To enter a PSD, select the solid component from the list (useful if there are different types), then
click on ‘Edit’.
The window on the right should appear, Figure 9-2. In this window you can change the Particle
Density; this is the density of the particle not the fluid mixture.
For InSize, only the Minimum Particle size needs to be entered above the table along with some
data points (cut offs) in the table (Particle Size, Mass %).
For Undersize and Oversize, both the Minimum and maximum particle sizes need to be entered
above the table along with some data points (cut offs) in the table (Particle Size, Mass %).
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If the Discrete PSD is only a simplified version of the distribution a ‘Fit Type’ option may be
selected. If you are unsure of what fit to use simply click on ‘AutoFit’, this will bring up the given
distribution and the fit types on a Log-Log Plot for you. Simply select the correct one for the
application.
NOTE: This distribution graph will only appear for the ‘Mass Percentage’ basis Distributions.
Once this has been done, click ‘OK’, located at the base of the window. The window will now close
and the distribution will show in the table shown in Figure 9-2, above, the Calculations status
(bottom right with a coloured strip) will still say ‘PSD was Not Calculated’. To finish this up click
the ‘Calculate PSD’ button on the bottom left of the window. The Calculation status bar should
turn green and should ‘PSD was Calculated’. The PSD has now been fully defined and ready to be
separated.
The particle size distribution may be inputted using one of the models in the ‘Input PSD’ options
menu on the left of the window; these are shown below.
Log Probability will only ask for a Mean Diameter and a Standard Deviation.
Click ‘Calculate PSD’ to finish.
NOTE: Refer to a text book for these understanding of these distribution parameters.
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9.2 Determining what Solids Operation to use
This is an important part of the process design stage. However for this step we will only be looking
at the solvent, Particles and recovery.
If the solvent is only a liquid (water, ethanol, etc.), use a Hydro-cyclone or a Rotary Vacuum filter.
If there is both a liquid and a solid solvent (ethanol near boiling or water/air mixture, etc.), use a
Simple solids separator, or split the two phases using a phase separator then separate treatments for
each solvent type.
If the particle size is primarily less than 0.1 mm in a gas, a Cyclone will not be effective, so use a
Baghouse filter.
Density is important in terms of what the difference between the solvents density and the particles
density are what allows for the separation to take place.
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9.3 Operations
There are several types of Solids separators. These are shown solved
with streams and the sub-toolbar with the symbols that match the
operations in the worksheet on the right in Figure 9-3.
9.3.2 Cyclone
This is the most common type of gas suspended solids separation device. These are used for
medium particle size separations. Defining a cyclone is easy once the PSD has been completed.
In the Design, Solids menu, select the solid that you wish to define as the basis of the separation.
Only in the cyclone can you select to separate the particles on a particle size distribution basis.
To select the ‘particle size distribution efficiency’ option select the option from the left of the
window in the ‘Efficiency Basis’ options box.
NOTE: To select a custom cut size select the cut size in the Solids menu before connecting up the
feed stream. Otherwise the default 1mm will be selected for you.
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Also changing the configuration between High-Efficiency, High flow and User defined will not
effect the calculations; but this will affect the sizing of the cyclone and potentially the limitations on
the efficiency of the cyclone.
There will be a restriction on the maximum efficiency based on the PSD and if there are any
particles less than 0.1mm in diameter.
The calculation method should not be changed until these calculations are understood of covered in
class.
9.3.3 Hydro-Cyclone
The Hydro-Cyclone is a similar device to the gas cyclone above but deals only with a liquid solvent
phase. Although the delta PSD calculations are not completed as in the cyclone, an overall
efficiency is calculated based on the ‘cut size’ or particle diameter. I.e. only a composition split is
calculated.
Defining the cycle time, submergence time %, De-watering % and a filter size parameter (diameter
or width/length) are the easiest way to completely solve this operation.
NOTE: Dewatering does not mean that there has to be water in the stream. The term is used
because water is usually the solvent used for this process.
NOTE: The size parameter does not need to be entered for the mass balance to be completed.
In the Rating, Cake menu there are several options. Most of these are only for sizing calculations;
however some of these parameters are for how much water is held in the solids phase (Cake
properties table). Leave the assumed values unless these are known or have been calculated from
tables or data.
This operation assumes that the physical filter is small enough to trap all of the solids. (i.e. there are
no solids in the liquids off stream)
NOTE: Change the options in the Rating, Sizing menu to change the filtration time (found in the
Performance, Results menu) to a reasonable time.
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10 Advanced Material
10.1 Pipesys
Pipesys is a third party operation that simulates pipes with more advanced options, profiles and
materials than that of Hysys. This should only be used when the pipe has specific properties that the
Hysys pipe function does not allow. For more finalised design
The basics for this operation are the same as the pipe function used above.
To start up Pipesys follow these few easy steps:
B18
B19
R5
Click on the ‘Piping Equipment’ Radio Button (B18), then click on ‘PIPESYS Extension’ (R5),
and finally click ‘Add’ (B19).
This should bring up Figure 10-2; this shows the connections tab and the instructions in the yellow
strip at the bottom.
Figure 10-2: The Worksheet View and the PIPESYS properties window
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From here just fill out the stream connections.
Move to the ‘Elevation Profile’ tab, as instructed in the yellow strip, and insert a pipe segment.
NOTE: The larger range of options available for the materials, construction and schedules.
Click on ‘View’, this will show a new window, Figure 10-3 below.
B20
Choose the ‘Nominal Diameter’ of the pipe. This is required; Hysys or Pipesys will not work it out
for you. Select 2 inches. (Industrial diameters are commonly in Inches or round numbers in mm). A
new box will appear this will ask for the ‘Pipe Schedule’.
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Select ‘40’ from the drop down menu; this is one of the most common schedules for chemical
plants.
The screen should look like the one in
Figure 10-4: The Dimensions Tab
above.
From the ‘Choose Roughness’ Cell select ‘PVC’ to keep similar to the above example
NOTE: The choices available such as Steel, Concrete, Iron and Fibreglass
Next we need to define the heat transfer. Go to the ‘Heat Transfer’ Tab, shown in
Figure 10-5 above. From here we define the conditions around the pipe.
Select the “Above Ground” radio button from the top left option box (Heat Transfer Environment)
Define the ‘Default Conduciveness’ as PVC in the drop down menu.
Then we need to define the Air Properties. This can be done by selecting the property and clicking
the “Default” button (B20)
We will not define a ‘Pipe Coating’, (Insulation), at this stage but the process is simple. Next we
need to close this window and return to the ‘Elevation Profile’ screen. Now we need to define the
pipe length and elevation changes.
Enter the figures in Table 10-1 below.
The warning in the yellow strip will now change to “Insufficient Information on the Temperature
Profile screen”. To solve this co to the “Temperature Profile” tab. Insert “25 oC” into the
“Ambient Temperature” cell of the table.
The warning in the yellow strip will now change to “Insufficient Information in the Attached
Streams”. To solve this co to the “Worksheet” tab. Insert the following information from Table
10-2.
From here the Operation should solve. This gives an outlet pressure of 173.5 kPa, with an energy
transfer of around 0.6 kW and a negligible temperature change.
To View the profile results go to the ‘Results’ tab and click on one of the three viewing options.
(Detail, Report, Plot).
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11 Not so Clever Applications of Hysys
The following section makes fun of Hysys bad side. Most of these things have been seen over the
years so don’t make the same mistakes as some unfortunate students who brought these to the
attention of the Tutors. Only a couple of very common examples are here but there are many more
including compressing combustible materials like the reactor inlets for the Brayton cycle. DO NOT
GET CAUGHT MAKING ERRORS OF THIS MAGNITUDE.
For a counter current exchange the LMTD would be 24.66. For a co-current exchanger the
DeltaTin/DeltaTout would be -1/3. This example defies the thermodynamic laws. Looking at this
temperature profile should ring alarm bells straight away. You cannot boil steam using the heat
from making ice. This is why I use the item tables to show the temperatures of the streams
whenever I am changing a condition that will effect such a unit.
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TUTORIALS AND WORKSHOPS
PIPE WORKSHOP ........................................................................................................................................................ 23
PIPE TUTORIALS......................................................................................................................................................... 31
PUMP TUTORIAL ........................................................................................................................................................ 45
HEAT EXCHANGER TUTORIAL.............................................................................................................................. 48
MASS TRANSFER TUTORIAL .................................................................................................................................. 53
COMPRESSION TUTORIAL ...................................................................................................................................... 61
TURBINE TUTORIAL.................................................................................................................................................. 65
SINGLE-STAGE RANKINE CYCLE TUTORIAL ................................................................................................... 69
MULTI-STAGE RANKINE CYCLES TUTORIAL................................................................................................... 70
SIMPLE BRAYTON (GAS) CYCLE TUTORIAL ..................................................................................................... 72
REFRIGERATION TUTORIAL .................................................................................................................................. 79
SEPARATION WORKSHOP ....................................................................................................................................... 98
SEPARATION TUTORIAL.......................................................................................................................................... 99
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