Aspen HYSYS Manual

1
 CHE 306
Chemical Engineering Laboratory IV
Term Paper on
Aspen HYSYS Manual

Submitted to
Dr. Md. Iqbal Hossain,
Assistant Professor
Mr. Ahaduzzaman
Lecturer
Mr. Md. Nazibul Islam
Lecturer
Mr. Noor Mohammad
Lecturer
Oindrila Hossain
Lecturer
Department of Chemical Engineering, BUET.

Date of Submission: 12th July, 2017

Submitted by
Tasnuva Farheen (1302001)
Shuvashish Mondal (1302002)
Md. Fahimul Islam (1302003)
Atique Ahmed Khan (1302004)
Mahmudul Hasan (1302005)
Sadia Siddika Dima (1302006)
Samia Rahman (1302007)
Md Sakib Ferdous(1302008)
Abdullah Al Musabbir (1302009)
Maisha Mahpara Feroz (1302010)

2
Table of Contents

Topic Name Page Number

Introduction 01
Feed 02
Stream 03
Fluid Package 04
Mixer 06
Tee 07
Pump 09
Compressor 10
Expander 12
Cooler 14
Air Cooler 19
Utility 21
Heater 26
Solid Processing 27
Three Phase Separator 44
Flash Separator 48
Tank 54
Heat Exchanger 55
LNG Exchanger 57
Extractor 59
Rotary Filter 62
Normal Distillation 64
Shortcut Distillation 68
Reboiled Absorber 71
Three Phase Distillation 75
Reactions 80
Conversion Reaction 81
Conversion Reactor 84
Gibb‟s Reactor 87
Yield Shift Reactor 90
Equilibrium Reaction 94
Equilibrium Reactor 97
Component Spliter 100
Hydrocyclone Separator 103
CSTR and Plug flow reactor 106
Solving CSTR 107
Solving Plug flow reactor 110
Adjust Block 112
Set Block 118
Absorber 120
Valves and Control 122
Optimization 132
Oil Characterization 139

3
Introduction

Aspen Hysys is a widely used simulation tool that provides users flexibility and powerful
approach in modeling different chemical process. Strong thermodynamic foundation has
contributed to its unparallel accuracy and interactive operation. For these reasons, this
software is used in universities and industries for research, development, modeling and
design.

This manual is intended for users who want to be a part of this great engineering platform.
Here, in each chapter example problems are used to illustrate some of the basic concepts of
building a simulation in Hysys. The tutorials presented here will guide users step by step
through the complete construction of a Hysys simulation.

As Hysys is a huge and complex simulator it is impossible to complete all segments of it in

one manual. This manual focuses primarily on the fundamental of Hysys. It is believed that
once these foundations are well understood, users will be able to learn advanced topics easily
by using the information in the Help menu.

Hysys, like most other software, is continually being developed and new versions are
released frequently. However, this manual covers Hysys version 2006. It is assumed that the
software is installed on the computer and the user has basic knowledge of operating the
computer.

4
Feed

At first various components in the process should be added. The components manager can be
accessed by selecting the components tab from the simulation basis manager.

Steps are as follows –

1. Click add
2. To add pure components write the component name in the match cell
3. To remove any component from the component list click remove

5
Stream

At first the input component should be entered as a feed stream which will be deal with. As
an example here methane, O2, CO2and H2O are taken.

Steps are as follows –

1. First select material stream icon from the object palette

a.
2. Then enter the stream properties such as temperature, pressure, molar flow rate etc.

3. After that the compositions of the input stream should be given.

6
Fluid package

All necessary information related to components and physical property calculation is

contained within the fluid package. It allows defining all the information in a single entity.
There are different types of fluid packages- Peng-Robinson, NRTL, UNIQUAC etc. Peng-
Robison is ideal for hydrocarbon systems. NRTL is used for liquids, chemical systems and
HF alkylation with highly non-ideal chemicals. UNIQUAC can be applied to a wide range of
mixtures containing water, alcohol, nitriles, amines, esters, ketones, aldehydes and
halogenated hydrocarbon.

Steps are as follows –

1. Click on the fluid package bar in the simulation basis manager

2. Click add

7
3. Choose appropriate fluid package from property package selection

8
Mixer

Mixer is used to mix feed streams. Some processes require several feed streams to be
properly mixed before a reaction is commenced in a reactor. Other processes require that
final products are blended together. Mixers serve to achieve both of these roles. Materials in
all physical states are capable of being mixed together, whether it is gas mixing, liquid
mixing, gas-liquid mixing or solid-liquid mixing.

Steps are as follows –

1. First select mixer icon from the object palette

2. Then insert inlet and outlet streams in connections

9
Tee

Tee is used to split a feed stream into several streams. Sometimes it is necessary to split a
stream into different ratio in this case tee can be a useful tool.

Steps are as follows –

1. Select tee icon from the object palette

2. Define inlet and outlet streams

10
3. Click on parameters
4. Insert the flow ratios of the outlet to split the inlet in desired amounts

11
Pump

Pump is used to increase pressure of inlet liquid stream (the inlet stream must be liquid).

Steps are as follows –

1. Select pump icon from the object palette

2. Define inlet, outlet and energy stream

12
3. Click on parameters
4. Specify Delta P or directly the pressure of outlet stream can be specified directly and
click on, if it is not done pump will not boost the stream, pump will work with 0.00 Delta
P.

Compressor

Compressor is used to increase the pressure of a stream (the stream must be gas, vapor).

Steps are as follows –

1. Insert the compressor icon from the object palette

2. Define inlet, outlet and energy stream

13
3. Click on worksheet to specify the duty

4. Click on parameters

14
Expander

The expander is used for decrease the pressure of stream (the stream must be gas, vapor
phase).

Steps are as follows –

1. Select the expander icon from the tools palette

2. Define inlet, outlet and energy stream

15
3. Click on worksheet to specify the duty

4. Click on design parameters

16
Cooler

Almost in every somehow and somewhere heat is being generated which needs to be cooled.
Cooler is mainly used in the purpose of cooling. To use a cooler in „Aspen Hysys 2006‟
follow the process-

1. Go to toolbar. The cooler symbol is given below.

2. Drag „cooler‟ from the toolbar to the case sheet

3. Double left click on mouse, a dialogue box will pop up with a „red block‟ in the bottom as
given below –

4. Now to add inlet, outlet and energy streams, you can newly create them or use existing
one. To add a stream, follow previous lecture.
5. After you have defined the streams go to parameters, set a value of „Delta P‟ (set to zero
if not said). You may also input energy if outlet temperature of cooler is unknown but if
you set values to both it will lead to consistency error (over specified).

17
6. After doing all these the bottom „red block‟ will turn into „green‟ with „OK written inside
it if it converges. The cooler with all necessary streams will look as shown below –

Too see how one variable changes with other-

1. Go to „Tools‟. You will find this in the uppermost menu.

2. Then „Databook‟. A new window will pop up like below

18
3. Go to „Insert‟. „Variable Navigator‟ window will pop up

4. In „Object‟ select the equipment or stream related form the list given there. Then
select the variable from the „variable‟ section. Also select „Variable Specifics‟ if
available. Select „Add‟. Your variable is now added to „Variables‟ in „Databook‟.
5. Similarly add another stream or equipment with which you want to vary your added
previous one.

19
6. Close the „Variable Navigator‟ window.
7. In „Databook‟ window go to „Case Studies‟. „Add‟ new case. You will see your object
in the window. Mark independent and dependent variable which is written as „Ind‟
and „Dep‟ respectively.

8. Now click „View‟, „Case Studies Setup-Main‟ will pop up. Selct „Upper Bound‟,
„Lower Bound‟ and „Step Size‟. It is recommended to set „High bound‟ to the value
that you have used in the stream of independent variable.

20
9. Select „start‟. Then click „Results‟. By default, a graph will pop up. You can also
change it to table and transpose table.

21
Air Cooler

Air cooler is one type of cooler which is used when the temperature need not to be decreased
more than 5oC. To use a cooler in Aspen Hysys 2006 follow the steps –

1. Add air cooler.

2. Double left click on air cooler and select „Process Stream Inlet‟ and „Process Stream
Outlet‟.

3. Now go to Design>Parameters.
4. Set „Process Stream DeltaP‟ to a desired value (zero if not given).
5. Set „Air Intake Temperature and Pressure‟ to a given value. You can also set „Air Outlet
Temperature‟ instead of „Air Intake Temperature‟. Give the outlet stream temperature.
Then the „air cooler‟ will converge. The window is as given below-

22
6. You can also edit some other variables which are written in „blue color‟.
7. In „Performance‟ you can see many properties (e.g. LMTD, UA and so forth) as shown in
the figure

23
Utility

To see the utilities of a stream

1. Double click on the stream. Go to „Attachments‟

2. Go to „Utilities‟.

3. Select „Create‟.

24
4. Select the utility that you want to know about from the „Available Utilities‟ window.

5. Select „Add Utility‟.

6. Now go to „Performance‟.

25
7. You can see many other properties there. You can also see the plots.

Too see pipe sizing –

8. In step 4 select „Pipe Sizing‟ and then “Add Utility‟

26
9. In „Calculation Type‟ you can select either „Max. Diameter‟ or „Pressure Drop‟. If you
know the „Pressure Drop‟ then select „Max Diameter‟ and vice versa. Once you enter any
of the two values the window will look like this –

10. In „Performance‟ you can also see, „Reynold Number‟, „Friction Factor‟, „Pressure Drop‟,
„Viscosity‟, „Density‟ and many more properties of the fluid in the pipeline.

27
To see Dew Point and Bubble Point temperature

1. Double click on a stream

2. In „Worksheet‟ input „Pressure‟ at which you want to know the corresponding dew point
and bubble point temperature
3. Set „Vapor Fraction‟=1 for „Dew Point‟ calculation.

4. Set „Vapor Fraction‟=0 for the calculation of „Bubble Point‟.

28
Heater

Heater is opposite equipment of cooler. Heater is used when heat energy or temperature is
needed to increase. To use a heater in „Aspen Hysys 2006‟ follow the process described for
„cooler‟. The only difference is, use a „Heater‟ instead of a „Cooler‟. The heater symbol is
given below.

29
Solid Processing

Creating Solid Hypotheticals

HYSYS allows users to create non-library or Hypotheticalcomponents from the Hypo

Manager. Hypothetical componentscan be pure components, defined mixtures, undefined
mixtures or solids. HYSYS library components can also be converted into Hypotheticals,
which allows modifying the library values.

The Hypo Manager is located on the Hypotheticals tab of theSimulation Basis Manager. It
can also be accessed via the Hypomanager button from the Components tab under
hypotheticalcomponents.

A wide selection of estimation methods are provided for thevarious Hypo groups
(hydrocarbons, alcohols, etc.) to ensurethe best representation of behaviour for the
Hypotheticalcomponent inthe simulation. In addition, methods are providedfor estimating the
interaction binaries betweenhypotheticalsand library components. You can also use
Hypotheticals can also be used with theTabular Package, as well as in Reactions.

In HYSYS, Hypothetical components exist independent of theFluid Package. When a

Hypothetical is created, it is placed in aHypo Group. From the Hypo Manager, new
HypoGroups can be created and then Hypothetical components can be moved within the
HypoGroups. Hypo Groups can also be imported and exported, thusmaking them available to
any simulation case.

Since Hypothetical components are not exclusively associatedwith a particular Fluid

Package, it is possible for multiple FluidPackages to share Hypotheticals. In other words, a
Hypothetical will be created once, and it can be used in any FluidPackage throughout the
case.

30
To create solid hypotheticals we have to follow the following steps:

1. Click on new case and select Hypotheticals tab from the Simulation Basis Manager.

31
The available commands for this group (accessed using the associated buttons) are as
follows:

Button Description
View Accesses the Hypo Group property view
for the selectedgroup.
Add Adds a Hypothetical Group to the present
case.
Delete Deletes the selected Hypothetical Group
from the case.
Translocate Searches through all of the
hypotheticalcomponents in thecase and if
there are duplicates HYSYS replaces them
andputs all the duplicates in a separate
Hypo group which thencan be deleted.
This is intended for use when large cases
have had largenumbers of templates/fluid
packages imported and thereare lots of
repeated hypotheticals in the case.
Import Imports a Hypothetical Group from disk.
Export Exports the selected Hypothetical Group
and saves it to afile, so that it can be
retrieved at a later time.

32
2. Select Add button to add a Hypo Group. The following property view appears.

3. On the Hypo Group property view, enter Cas the new Group Name. In the component
class, drop down list, select Inorganic.

4. Now, install a Hypothetical or solid component. From the Individual Hypo Controls
group, click the Add Solid button. This adds a Solid component and automatically
names it Hypo20000*.

33
5. Enter a new name for this component by selecting the Name cell typing C. In the MW
cell and Liq Density cell specify molecular weight and density of Carbon and click on
Estimate Unknown Props button.

34
6. From the Individual Hypo Controls group, click the Viewbutton to access the
component property view. Then select Props button to see its properties.

7. Click the Closeicon to return to the Hypo Group propertyview.

8. Click the Close icon and HYSYS returns you to the Hypotheticals tab of the
Simulation Basis Manager. The solid carbon has created.

35
Solid Separation Operations

After creating solid hypotheticals, HYSYS also allows users to carry solid separation
operations. The object that is used to separate solids from liquid solid or gas solid mixtures is
solid ops object palette. In this palette five types of separators are found. They are:

1. Baghouse Filter
2. Cyclone
3. Simple Solid Separator
4. Hydrocyclone
5. Rotary Vacuum Filter

Baghouse Filter

Baghouse Filter is used when the feed is a mixture of solid and gas. This model is based on
empirical equations. Itcontains an internal curve relating separation efficiency toparticle size.
Based on the particle diameter, the reported separation efficiency for solids is determined
from thiscurve. The solids being separated must be previously specifiedand installed as
components in the stream attached to thisoperation.

For building the simulation with Baghouse Filter following steps to be followed:

1. Create solid hypotheticals and add them to the component list by following the steps
mentioned earlier.
2. Choose Peng-Robinson as the fluid package and click on Enter simulation
environment button.
3. Add a feed stream that has the following specifications.

36
4. Click on the Solid Ops icon . The Solid Operations Palette appears.

37
5. Double click the Baghouse Filter icon
6. The Baghouse Filter property view appears. Insert the following information in it:

38
Cyclone
The Cyclone is used to separate solids from a gas stream and isrecommended only for
particle sizes greater than 5 microns. It consists of a vertical cylinder with a conical bottom,
arectangular inlet near the top, and an outlet for solids at thebottom of the cone. It is the
centrifugal force developed in thevortex which moves the particles toward the wall.
Particleswhich reach the wall, slide down the cone, and so becomeseparated from the gas
stream. The solids being separated mustbe previously specified and installed as components
in thestream attached to this operation. The main advantage of Cyclone separator is pressure
drop is much less than that of Baghouse Filter.
For building the simulation with Cyclone, following steps to be followed:
1. Create solid hypotheticals and add them to the component list by following the steps
mentioned earlier.
2. Choose Peng-Robinson as the fluid package and click on Enter simulation
environment button.
3. Add a feed stream that has the following specifications.

39
4. Click on the Solid Ops icon . The Solid Operations Palette appears.

a.

5. Double click the Cyclone icon

6. The Cyclone property view appears. Insert the following information on Connections
page of Design tab:

40
7. Go to the Parameters page and specify particle efficiency.

8. Specify the solid characteristics on the Solids page. This page contains two different
data, depending on the radio button selected in the Efficiency Basis group. Here,
Single Particle Diameter efficiency basis is selected and the name of the solid
hypothetical already installed in the case is provided.

41
42
Simple Solid Separator

The Simple Solid Separator (Simple Filter) performs a non-equilibriumseparation of a stream

containing solids. Thisoperation does not perform an energy balance, as the separation is
based on the specified carryover of solids in the vapor and liquid streams, and liquid content
in the solidproduct. It should be used when you have an existing operationwith known carry
over or entrainment in the product streams.The solids being separated must be previously
specified andinstalled as components in the stream attached to thisoperation.

For building the simulation with simple solid separator following steps to be followed:

1. Create solid hypotheticals and add them to the component list by following the steps
mentioned earlier.

2. Choose Peng-Robinson as the fluid package and click on Enter simulation

environment button.

3. Add a feed stream. (Feed should be a mixture of vapor, liquid and solid)

4. Click on the Solid Ops icon . The Solid Operations Palette appears.

5. Double click the Simple Solid Separator icon

6. The Simple Solid Separator property view appears. Insert the name of the inlet, vapor
product and solid product on Connections page of Design tab

43
7. On the parameters page, specify pressure drop.

8. On the splits page, choose the split method by defining a type of fraction.

44
45
The types of fraction are described in the table below:

Object Definition
Split Fractions Specify the fractional distribution of solids
from the feedinto the vapor and liquid
product streams. The solidsfraction in the
bottoms is calculated by HYSYS. The
fraction of liquid in the bottoms must also be
specified(solidproduct).
Stream Fractions Enter the mole, mass or liquid volume
fraction specificationfor each of the
following:
• Total vapor product solids fraction on the
specifiedbasis.
• Total liquid product solids fraction on the
specifiedbasis.
• Liquid phase fraction in the bottom product.

After converging the property view appears like this:

46
Three Phase Separator

A three phase separator operation is used to separate a feed stream into three streams
according to phase. A vapor-liquid-liquid equilibrium is reached in the vessel at a certain
temperature and pressure. When the feed pressure is higher than the vessel pressure, a flash
operation occurs in the vessel producing the three phases; otherwise, withdrawing heat from
the feed stream produces the three phases. The three phases are then separated into a vapor
stream, a light liquid (organic) stream and a heavy liquid (aqueous) stream. The conceptual
diagram for the three phase separation operation is given below for a steady state system.

For building the simulation of three phase separator several steps that have to be followed are
given below:

1. Add components and choose Peng-Robinson as the fluid package.

2. Click on Enter simulation environment if you are ready for building simulation.
3. Add a feed stream that has the following specifications –

47
4. Double click on valve button on object palette.
5. On the connections page, insert the following information:

48
6. Click on the parameters page and insert pressure drop in the valve.

7. Double click on three phase separator button on object palette.

8. On the connections page, specify the following information:

49
9. Go to the worksheet tab to see the results:

50
Flash separator

Flash separation is a process where part of a feed stream vaporizes and vapor and liquid in
equilibrium are separated. In steady state mode, the separator divides the vessel contents into
its constituent vapor and liquid phases. The vapor and liquid in the vessel are allowed to
reach equilibrium, before they are separated.

A flash separator is used to determine the product conditions and phases. The pressure at
which flash is performed is the lowest feed pressure minus the pressure drop across the
vessel. The enthalpy is the combined feed enthalpy plus or minus the duty.

The separator has the ability to back calculate results. In addition to the standard application
(completely defined feed streams being separated at the vessel pressure and enthalpy), the
separator can also use a known product composition to determine the compositions of other
product streams and by a balance the feed composition.

For building up the simulation, a problem statement is given below: A stream containing 15%
ethane, 20% propane, 60% i-butane and 5% n-butane at 500 F and atmospheric pressure has a
flow rate of 100lbmole/hr. This stream is to be compressed to 50 psia and then cooled to
320F. The resulting vapor and liquid are to be separated as the two product streams. What are
the flow rates and compositions of these two streams?

1. Add components and choose Peng-Robinson as fluid package.

2. Click the Enter Simulation Environment button when you are ready to build the
simulation.
3. Add a feed stream having following specifications:

51
4. Double click on the compressor button on the object palette.
5. On the connections page, enter the following information:

6. Go to the Worksheet tab. At the conditions page, specify pressure for the comp gas as
50 psia.

52
7. Double click on the cooler button on the object palette.
8. On the connections page, enter the following information:

9. Switch to the parameters page and specify pressure drop.

53
10. Switch to the worksheet tab. At the conditions page, specify temperature for the
cooled gas which is 320F.

11. Double click on the separator button on the object palette.

12. On the connections page, enter the following information:

54
13. Go to the worksheet tab to preview the results:

55
The whole simulation file is shown below:

56
Tank

The operating criteria for tank are same as flash separator. Multiple feed streams can be used
and after operation liquid and vapor product streams are separated. The tank is generally used
to simulate liquid surge vessels.

The previous problem can also be solved by using tank. Everything will be same up to step

10. Then, double click on tank button on the object palette and at the connections page,
enter the following information:

Same result is found in this case.

57
Heat exchanger

A heat exchanger is a device used to transfer heat between a solid object and a fluid, or
between two or more fluids. The fluids may be separated by a solid wall to prevent mixing or
they may be in direct contact. They are widely used in space heating, refrigeration, air
conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries,
natural-gas processing, and sewage treatment.

The steps are as follow –

1. First of all we need to select our components and corresponding fluid package.

2. Then we enter the simulation environment where we first input the feed streams

3. Then we left click the heat exchanger icon at the right side

58
4. Then we double right click to enter the heat exchanger and we select design where we
determine our shell and tube side inlet outlet depending on the viscosity corrosiveness
and other properties of the fluids that we are using.
5. Then we go to parameters where we give values of pressure drop and heat duty as 0. Now
for the heat exchanger to solve we have 2 options either we give value of the overall heat
transfer co-efficient in parameters

59
LNG exchanger

The steps are as follow –

1. Select required components and suitable fluid package, then create hot and cool fluid feed

2. Then select the LNG exchanger

3. Next double left click on the LNG exchanger and give names to the inlets and outlets and
values of pressure drops are 0 unless said otherwise

60
4. Give the properties of the outlets as in what is the expected temperature of any of the
outlets

61
Extractor

Liquid–liquid extraction, is a method to separate compounds based on their relative

solubilities in two different immiscible liquids. It consists of transferring one or more solute
contained in a feed solution to another immiscible liquid (solvent).

The steps are as follows –

1. Select the components and fluid package

2. Then create the feed liquid and the solvent giving them the compositions and the
conditions as expected.

3. And select the liquid-liquid extractor

4. Then we double left click the extractor and give the names of overhead and bottom inlets
and outlets

62
5. Then press NEXT after that give pressures of top and bottom

6. Again press NEXT

7. After that press DONE, then come to this page

63
First it remains unconverged after pressing the run button it becomes converged.

64
Rotary filter

It consists of a drum rotating in a tub of liquid to be filtered.The technique is well suited to

slurries, and liquids with a high solid content, which could clog other forms of filter.

The steps are as follow –

1. Select components and fluid package as usual and we enter the simulation
environment

2. Select the rotary filter. Then double left click the rotary filter and give the inlets and
outlets

3. Give the size of the filter for it to converge

65
4. We can also give the properties of the cake to determine size

66
Normal Distillation

Normal distillation is used for speration of simple binary component system based on their
relative volatility. This process has vast applications in practical life from refining oils to
producing pharmaceuticals etc.

Suppose an ethanol water mixture has to be distilled where 30 kmole/h distillate product
containig 80 mole% ethanol is produced and reflux ratio here is 2.5. The steps are given
below –

1. Add components and choose NRTL fluid package.

2. Add a feed stream.
3. Click on distillation column in object pellete

4. Double-click on distillation column and the column property view will appear.

5. Now specify inlet, condenser energy stream,boiler energy stream, condenser type and
stage numbering. When specifying all these parameters are finished, click on Next
button.
6. Specify condenser pressure, condenser pressure drop and reboiler pressure and click on
Next.

67
7. As condenser temperature, top stage temperature and reboiler temperature estimation
are optional you can ignore it and click on Next button again.

68
8. Specify reflux ratio and then click on Done option.

9. An unconverged dialogue box will appear. Go to the monitor page and specify distillate
rate.

69
10. Activate this specification and click on Run button. After sometime, the system will
converge.

11. Finally, click on Performance tab and see the results.

70
Shortcut Distillation

Shortcut distillation column is used for multicomponent distillation. It is only an estimate of

the Column performance and is restricted to simple refluxed Columns. For more realistic
results the rigorous Column operation should be used. This operation can provide initial
estimates for most simple Columns.
Suppose a 1000 kmole/h feed stream containing equimolar methane, ethane, propane, butane,
ethanol and water needs to be distilled. The steps to be followed for this process is given
below-
1. Add all components and use NRTL as fluid package.
2. Add a feed stream which will have the following specifications.

3. Click on shortcut distillation column in object pellete.

4. Now double-click on the shortcut distillation column and column property view will
appear.

71
5. In the connection page of design tab, specify inlet, overhead vapor, bottom,
condenser duty, reboiler duty and top product phase. Remember overhead product
can be overhead vapor or distillate stream depending on the button selected on the
top product phase group.
6. Now go to the parameter page and specify light key in bottoms and heavy key in
distillate, condenser pressure, reboiler pressure, external and minimum reflux ratios.

7. The system has converged and now you can click on performance tab for the final
results.

72
73
Reboiled Absorber

Reboiled absorber is used to vaporize minute amount of a component from a feed stream.

Suppose, we have two feed streams and an energy stream. The steps to be followed to
converge Reboiled absorber are given below:

1. Add components and choose Peng-Robinson as fluid package.

2. Add a feed stream with the following specification –

3. Add another feed stream with the following specifications.

74
4. Add an energy stream 2.1e 06 kJ/h

5. Double click on the Reboiled Absorber icon in object pallet. The first input expert
view appears. Specify top stage inlet, optional inlet streams overhead vapor, bottom
liquid outlet and reboiler energy streams. Click on next button.

75
6. Specify top stage and bottom stage pressures. Click on next button.

7. Then a dialogue box containing optional temperature in condenser and reboiler

appears. You can neglect it by clicking next. Then click on done button.
8. Now go to the Monitor page in the design tab and specify overhead product rate.
Click on the run button. After sometime, the system will converge.

76
9. Go to performance tab to see the final result.

77
Three Phase Distillation

When dealing with three phase systems, it is necessary to use adifferent type of column that
uses a different Input Expert, and adifferent default solver.
The three phase system in this example consists of a 2-butanol, water,n-butyl-acetate system.
The feed to the column is saturated liquid atatmospheric pressure. The liquid product from
the condenser is 98%pure water, and the liquid product from the reboiler is a mixture of
thetwo other components (2-butanol and n-butyl-acetate). The steps are given below:
1. Add components and choose NRTL as fluid package.
2. Add a feed stream having following composition

3. Double click on Three phase distillation column in object pellete

.
4. Column property view will appear. Select the Distillation radio button and press the
next button.

78
5. On the next page, set the number of stages at 6, and set the "Two Liquid Phase
Check" on the top five stages.

6. On the third page, enter names for the streams around the condenser. For this column,
the Reflux Stream will be the Lights only; therefore, select the appropriate radio
button in this group box.

79
7. On the fourth page, specify the vapour rate the Light Reflux Fraction. The degrees of
freedom should read 0, once both of these values are entered.

8. On the fifth page, attach the Feed stream. Also, define the reboiler energy stream and
attach a liquid product stream to the reboiler.

80
9. On the next page, specify condenser pressure and reboiler pressure.

81
 10. Then you can either supply optional temperature estimate or not which depends on
you.

11. Then press done button to close the input expert.

12. Finally go to the monitor page in design tab and specify bottom product rate. The system
should converge.

82
Reactions

Various reactions such as conversion, equilibrium, heterogeneous catalytic, kinetic and

simple rate reactions can be handled in HYSYS with various reactors such as Gibbs reactor,
equilibrium reactor, conversion reactor and yield shift reactor.

Consider the following reaction:

CH4 + 2O2 = CO2 + 2H2O

The steps are as follows:

1. Add the components and fluid package as usual.

2. Click on the Reactions tab in Simulation Basis Manager.
3. Click Add Rxn.

83
Conversion Reaction

No thermodynamic knowledge is required for this reaction type. The reaction will proceed
until either the specified conversion is achieved or the limiting reagent is consumed.

1. Click on the desired reaction (here conversion reaction is selected as an example).

2. Click on Add Reaction.

3. Add the required components.

4. Add the stoichiometric coefficients of the components in the reaction in Stoich Coeff.
5. Click on Basis.

84
6. Select the Base Component and Rxn Phase as required.
7. Select the conversion (%).
8. Return to Simulation Basis Manager.
9. Select desired reaction.
10. Click Add set.

11. Select the reaction in Active List.

12. Click Make Active.

85
13. Select the set and click Add to FP.
14. In Simulation Basis Manager click Return to Simulation Environment.
15. Add different streams for different reactants.

86
16. Mix the streams using mixer.

Conversion Reactor

1. Click on General Reactors in object palette. The symbol looks like the one shown below:

87
2. Select Conversion Reactor.

3. In the Design tab give the inlets, vapor and liquid outlets.
4. Click Reactions.

88
5. Insert the Reaction Set. The green bar will appear if the reactor converges.

89
Gibb’s Reactor

1. Add components, fluid package and reaction sets as before.

2. Add streams having reactants at desired conditions.
3. Pass the streams though a mixer in the same way as before.

4. Select General Reactors from object palette.

5. Click Gibbs Reactor. The symbol looks like the one shown below:

90
6. In Design (Connections) insert the desired Inlets, Vapor Outlet and Liquid Outlet.
7. In the Reactions tab various kinds of reactor can be chosen.

8. Choose Gibbs Reactions Only, when reaction stoichiometry is unknown.

91
9. Choose Specify Equilibrium Reactions when the stoichiometry is known. It is alternative
to equilibrium reactor.
10. Choose No Reactions in case of phase equilibria calculations only. It acts like a separator.

92
Yield Shift Reactor

The Yield Shift reactor unit operation supports efficient modeling of reactors by using data
tables to perform shift calculations. The operation can be used for complex reactors where no
model is available, or where models that are too computationally expensive.

Consider the following reaction:

C2H6 = C2H4 + H2

1. Select components, add fluid package and the reaction as before.

2. Click Enter Simulation Environment.
3. Add the feed stream.

4. Select Yield Shift Reactor. The symbol is the one shown below:

5. Click on the yield shift reactor.

93
6. In Design (Connections) enter the Feed Streams and Product Stream.
7. Click on Parameter.

8. Enter the Pressure Drop.

94
9. Click on the Model Config tab.
10. Enter a Name, Value and Unit type from various types available in Design Parameter
option.
11. Click on composition Shift and select Base Yields.

12. Choose Use yield only.

13. Enter the values of Base Yield, the summation should be equal to zero.
14. Click on Base Shifts.

95
15. Enter the values of Design variables in min, max, base and in various components. The
green bar indicates that the reactor has converged.

96
Equilibrium Reaction

The equilibrium reactor is a vessel that models equilibrium reactions. The outlet streams of
the reactor are in a state of chemical and physical equilibrium.

Consider the following reaction:

CH4 + H2O = CO + 3H2

1. Add the components and fluid package as usual.

2. In Simulation Basis Manager click on Add Rxn.

3. Select Equilibrium.
4. Click on Add Reaction.

5. Add the desired components

6. Add stoichiometric coefficients of the components.
7. Click on Basis.

97
8. If the K value is unknown, click on Library.

9. Select the desired reaction from the Library.

10. Return to Simulation Basis Manager.

98
11. Select the reaction and click on Add set.
12. Click on Add to FP.
13. Click on Enter Simulation Environment.

99
Equilibrium Reactor

1. Add the reactant streams and pass them through a mixer.

2. Select Equilibrium Reactor from General Reactors in object palette. The icon is shown
below:

3. In the Design (connections) tab, enter the Feed Streams (in this case the outlet stream
from mixer) and Product Streams.
4. Click on Reactions tab.

100
5. Enter the desired reaction set.
6. The temperature of the product streams can be changed by adding an energy stream in
Design (Connections).

7. Click on Worksheet

101
8. Insert the desired temperature of the product stream in Conditions option. The green bar
shows that the reactor has converged.

102
Component Splitter

As the name suggests, component splitter is used to split various components in a stream. It is
not applicable for any real-life application.

1. Select the Component Splitter in object palette. The icon is shown below:

2. Click on it.

3. Insert the inlets, Overhead Outlet and Bottoms Outlet.

4. Click on Splits.

103
5. Give the required values of splits in different streams.
6. Click on Worksheet.

7. Insert the appropriate temperature, pressure of the streams.

Recycle

A definite portion of a stream can be recycled by this application.

104
1. Select Recycle from object palette. The icon is shown below:

2. Select Inlet and Outlet streams.

Use the outlet stream as inlet stream in the mixer, with the incoming feed.

105
Hydrocyclone Separator

A hydrocyclone separator is a device to classify, separate or sort particles in a liquid

suspension based on the ratio of their centripetal force to fluid resistance.

The steps are as follows:

1. Add components as usual (inlet must contain one or more liquid component).
2. Click on hypotheticals.
3. Change component class to desired one such as inorganic, organic, salt etc.
4. Click on add solid.
5. Insert the solid density and molecular weight.
6. Click on Estimate Unknown props on top of the dialogue box.

106
7. Back to the component list click on hypotheticals and click on Add Group.
8. Add fluid package and enter simulation environment.

9. Select solid ops from component bar.

10. Select the third one from the top, hydrocyclone.

11. Go to design, select connection and insert Inlet, Solid Product, Liquid Product name.

107
12. Go to parameters and insert Particle Efficiency.

13. Go to solids and select the Solid Name created earlier. The green bar indicates that the
hydrocyclone has converged.

108
Continuous Flow Stirred Tank Reactor (CSTR) and Plug Flow Reactor
(PFR)

CSTR and PFR both are used for Simple Rate, Heterogeneous Catalytic and Kinetic
reactions. CSTR is usually used for liquid state reaction where PFR is used for reactions in
the gas phase.

Calculation in PFR and CSTR for kinetic reaction are done using the equations:

Keq=

The equilibrium constants are calculated by:

K = ATnexp(E/RT)

Heterogeneous catalytic reaction rate is calculated using the equation:

Where,

Kh= absorption parameter,

P*ym=Partial pressure,

E= activation energy,

DBED= Bed density

109
Solving Continuous Flow Stirred Tank Reactor (CSTR)

For solving a CSTR the values of A, E, A`, E` should be given or relevant values should be
assumed.

Consider the following kinetic reaction:

CO+H2O=H2+CO2

The steps for solving a CSTR reactor where the above reaction is occurring are:

1. Select the reaction components as shown previously to create the components list.
2. Select a fluid package (e.g, Peng – Robinson).
3. Go to reactions and select kinetic.

4. Add the stoichiometric coefficients.

110
5. Go to basis (Molar for liquid, Partial pressure for vapor phase).
6. Add Rxn phase (vapor or liquid).

7. Add parameters (the values of A, E, A`, E`).

8. Add the reaction to reaction set, and add reaction set to fluid package as shown before.
9. Enter Simulation Environment.

10. Click on the icon shown above to add a CSTR from the object palette.

111
11. Go to Design, select the connection tab and specify Inlet, Liquid Outlet and Vapor Outlet.
12. Go to Reactions, select required reaction and reaction set like other reactors.

13. Go to Rating, select sizing. There are two orientations in geometry, click on the desired
one.
14. Input any two from volume, diameter and height of the CSTR. The green bar indicates
that the reactor has converged.

*CSTRs are normally used for liquid – phase reactions, although the reaction here is in the gas phase.

112
Solving Plug Flow Reactor (PFR)

Consider the following reaction:

Toluene + Hydrogen = Benzene + Methane
The steps for carrying out this reaction in a PFR are as follows:
1. Select the reaction components as shown previously to create the components list.
2. Select a fluid package (e.g, Peng – Robinson).
3. Go to reactions and select kinetic.
4. Add the stoichiometric coefficients.
5. Go to basis (Molar for liquid, Partial pressure for vapor phase).
6. Add Rxn phase (vapor, since the reaction is in the gas phase).
7. Add parameters (the values of A, E, A`, E`).
8. Add the reaction to reaction set, and add reaction set to fluid package as shown before.
9. Enter Simulation Environment.

10. Click on the icon shown above to add a PFR from the object palette.

11. Go to connection, specify inlet and outlet stream, add an energy stream if necessary.
12. Select parameter and provide pressure drop in PFR.

113
13. Select Reactions, go to overall, choose reaction set.
14. Go to details, add reaction and choose the specification.

15. Go to rating and provide necessary dimensions such as total volume, length, diameter,
void fraction, void volume, wall thickness (any three information has to be specified, rest
would be calculated by HYSYS). The green bar indicates that the PFR has converged.

114
Adjust Block

Adjust block is used to get a desired output value by adjusting the value of any unit or
component. In a process, it is very often required to get a target output of any product. For
this any unit inside the process is adjusted.If the target variable is specified and the adjustable
value are left blank Aspen Hysys cannot solve the problem and system shows not solved
error.

Adjust block takes the adjusted variable and target variable and iterates the values to
converge within a specified range allocated by user.

Procedure of use is as follows:

1. First, we need to select components. Suppose Nitrogen and Water is selected.

115
2. Use the EOS fluid package filter and select PRSV package.
3. Enter the simulation environment.

4. Select a stream and name it inlet. Specify the temperature as 212 ⁰F, pressure as 174 psia
and molar flow as 100 lbmole/hr. The mole fractions of both components are set to 0.5.
The stream is now fully defined.

116
5. Select a valve and select the inlet stream as inlet and name the outlet stream as outlet. Due
to unknown pressure drop the valve is still unspecified.

6. Specify the pressure drop as 14.5038 psi. The green bar shows that the valve is
converged.

117
7. Select the separator from the object palette, select the outlet as the inlet stream to
separator and name the outlet vapor stream as vapor and outlet liquid stream as liquid.

8. We observe the outlet temperature of vapor is 98.5 ⁰C or 209.4 ⁰F. Assume that this
temperature is to be adjusted to 85 ⁰C by changing the pressure drop in the valve. The
value of pressure drop that will cause this vapor temperature to be 85 ⁰C is unknown.

118
9. For this the adjust option is selected from the palette and placed in the process flow
diagram (PFD) as shown above.

10. Click on the adjust block. In the connections tab, select the adjusted variable object as
VLV-100 and the variable as pressure drop.
11. Select the target variable object as the temperature of the vapor.

119
12. In the Parameters tab, select the minimum and maximum pressure as 10 and 1000 psi and
number of iterations as 10.
13. If a start button is displayed in the dialogue box, the adjustment will begin after clicking
on it.

14. The system is specified and it can be seen that the outlet temperature of the vapor is 185
⁰F or 85 ⁰C. The pressure drop in the valve is changed to 100.85 psi.

120
Set Block

Set block is used to vary one parameter with respect to other in a way one wishes.

Suppose a stream of ammonia and one of water are taken and mixedusing a mixer. During
specifying the stream,the input molar flow rate of ammonia was given as 20kilomole per hour
but the water flow rate was not specified. It was decided that the water flow rate will be three
times than the ammonia flow rate. For this the system remains underspecified and not solved.

Steps for using a set block are as follows:

1. The set block from the object palette is selected and placed as shown above.

2. Click on the set block.

3. In the Connections tab, set the target variable object as water and variable as molar flow
rate of water.

121
4. Select the source object as ammonia. The system is automatically specified assuming the
molar flow rate of water is equal to ammonia.

5. In the Parameters tab, select the multiplier as 3 and the system is as specified as desired.
The molar flow rate of water is now 60 kgmole/hour.

6. The PFD would look like the image shown above after adjustment.

122
Absorber

Absorbers are used to absorb one component by another. Suppose a stream of ammonia is to
be absorbed by water.

The steps for the process are as follows:

1. Select water and ammonia for the component list, then select a suitable fluid package.
2. Specify a pure stream of water and one of ammonia. As an example, the ammonia stream
is at 140 kPa and 25 ⁰C and the water is at ambient temperature and pressure.

3. Select the absorber from the object palette, which has the icon shown above.

4. Connect the liquid stream at the top and gaseous stream at the bottom. Name the overhead
stream as overhead and bottoms stream as bottoms. Then click next.

123
5. Specify the top stage pressure as 100 kPa and bottom stage pressure as 145 kPa, then
click next, and then click done.

6. Click on run when the above dialogue box appears. The green bar indicates that the
absorber has converged.

124
Valves and Control

A valve is a device for controlling the flow of fluids (liquids, gases, slurries) in a pipe. The
flow is controlled by means of a movable element that opens, shuts, or partially obstructs an
opening in a passageway. Control is an important factor in chemical engineering. In order to
understand control, it is important to know the types of variables which need to be controlled
first.

There are two types of variables:

1. Process variable / controller variable

2. Manipulated variable

Control systems are also of two types:

1. Feedback control
2. Feedforward control

Suppose a certain variable (e.g. temperature) of acid in a factory is to be kept constant. At the
same time, external factors are causing it to change (e.g. heat from the outside). There is a
way (a heat exchanger with water as the cooling fluid) to influence the variable. Now all that
is needed is to determine when to use it to keep the variable constant.

In this example,the rise and fall of the temperature is the Process. Determining when and to
what extent to influence it is the Control.

Temperature is called the Controlled Variable, the output of the system. Its desired value is
called the Set Point. Temperature is here also an Input Variable, since it is measured by a
thermometer to know the current value of temperature. The state of the heater is called the
Manipulated Variable, because it is manipulated by the system.

Since the output of this system is also used as input to the system, it is a Closed Loop system.
An Open Loop system would not have it. And since the temperature is used directly as an
Input Variable, it is a Feedback Control System. A Feedforward Control System would use a
variable that indirectly indicates the Controlled Variable as input.

The different types of controllers are:

125
1. On-Off Controller
2. P Controller
3. PI Controller
4. PID Controller

Only the PID controller will be discussed here. Proportional–Integral–Derivative controller

(PID controller) is a control loop feedback mechanism (controller) commonly used in
industrial control systems. A PID controller continuously calculates an error value as the
difference between a desired setpoint and a measured process variable and applies a
correction based on proportional, integral, and derivative terms (denoted P, I, and D
respectively) which give their name to the controller type.

For a PID controller,

Gc =kc [1+ +τds]

Here,

kC = Proportional constant

Gc = Gain

τd= Derivative constant

τd =Integral constant

126
The problem discussed above will now be solved using HYSYS. The steps to be followed
are:

1. Select components and create a stream. For this example, take H2SO4 and H2O as the
components.
2. Create two separate streams for each. Water is cold and the acid is the hot stream.

3. Insert a valve system after every stream. Specify the inlet and outlet of each valve.

127
4. Specify the pressure drop in each valve.

5. The acid is cooled using water. So, take a heat exchanger and insert acid in the tube side
and water in the shell side. Let the tube outlet temperature be 70 ⁰C. Put in the required
information for the heat exchanger as shown before so that it converges.

128
6. Insert a valve at both the tube side and shell side outlets.

7. Select the Control Ops option from the object palette (shown in the left image above), and
then select the PID controller (shown in the right image above).

8. Click on the PID controller.

9. Within the Connections tab, in the Process Variable Source box, click on select PV, then
select cooled acid as the object and Temperature as the variable.

129
10. In the Output Target Object box, select the water inlet valve (VLV – 101) as the object,
and the Actuator Desired Position as the variable.

11. In the Parameters tab, select the mode “Auto”.

12. Set a set point value. Here sp is 70 as we want to cool the acid to 70
13. Put in the value of Kc.
14. Select the range, which is the maximum and minimum value of the process variable.

130
15. The PID dialogue box would ultimately look like the image above.

16. The simulation file would look like the image above.
17. Before entering the dynamic mode, the steady – state simulation file must be saved.

In order to create a stripchart of the variable of any stream during the dynamic mode, e.g. the
cooled acid temperature, the steps are:

1. Click on the stream.

2. In the stream‟s dialogue box, click on the dynamics tab
3. Then select the stripchart option.

131
4. From the appropriate variable set, select the desired variable by selecting the set and then
removing the redundant variables.
5. Click on Create Stripchart.

6. An empty stripchart will appear.

132
7. In the Simulation menu, click on the Integrator option.
8. Fix the acceleration, real time and desired real time factor from the integrator dialogue
box.
9. Save the steady state simulation file.

10. Click on the dynamic mode icon shown above in the menu bar.

11. Then select Integrator active (the green button).

12. The stripchart should start showing some data like above.

133
During the integration,in order to see the varying of temperature, pressure, flow rate in a
table:

1. Right click on the stream.

2. Select show table.

134
Optimization

Optimization means to make the best use of the available resources. For process industries,
the word is applied in the same way; making use of reactants and manipulating the process
conditions to generate the most profit or the least waste, depending on the situation.

As an example, consider the problem below:

In order to optimize the profit, the following steps are to be followed:

135
1. The process flow diagram is constructed, which will look like the one above.

2. From the menu bar, click on Simulation, then on Optimizer.

3. Click on the object whose property is to be optimized.
4. Select the object‟s variable that needs to be optimized, then click OK.

136
5. In the Optimizer dialogue box, select the Variables tab.
6. Type in the lower and upper bounds of the variable, then click on Spreadsheet.
7. In the OptimizerSpreadsheet dialogue box, click on Spreadsheet again.
8. For convenience, the spreadsheet can be organized in the following way:

To input the precise value of the stream parameters, the following steps are followed:

9. Right-button click on the cell where the value is to be input.

137
10. Click on Import Variable.

11. Select the object, then select the variable of the object.

12. The imported stream values will be shown in black.

13. The summation of the heating duties is obtained by typing in the formula shown above.

138
14. The value calculated by HYSYS is shown in red.
15. The cost if the heating and cooling duties is found by typing the formula above.

16. The revenue is calculated in a similar manner. The formula is shown in the bar above.

139
17. The total revenue is found by summing the revenue from NGL and Residue Gas.
18. The profit is calculated by typing the formula shown in the bar.

19. From the menu bar, click on Simulation, then on Optimizer, then select the Functions tab
in the optimizer dialogue box.
20. Select the cell with the parameter to be optimized, select whether to maximize or
minimize the value, then click Start.

140
21. The maximum value after optimization is shown beside Current Value.

22. The Optimizer Spreadsheet can be accessed from the PFD window as well. It will display
the profit after optimization.

141
Oil Characterization

Crude grades vary considerably from each other - in yield and properties. Crude
characterization is essential to estimate feedstock properties for refinery units, produce an
optimal number of finished products, meet product quality specifications and to provide an
economic assessment for crude oils.Each crude is compared with the other feedstocks
available and, based upon the operating cost and product realization, is assigned a value. Oils
can be characterized using a variety of analytical techniques. Sulfur content, API gravity,
pour point, wax content, and viscosity are all used to give an evaluation of the overall
properties of an oil.

A crude assay is a detailed report which describes the properties of the whole crude, as well
as the major fractions into which a crude is distilled at the refinery - gasoline, naphtha,
kerosene, jet fuel, middle distillates, gas oils and residue. Typically, the data contained in a
crude assay includes yields generated from the physical distillation or simulated distillation,
specific gravity, gas chromatographic components, sulfur, nitrogen, viscosity, cold flow (pour
point, cloud point, freeze point), conradson carbon, refractive index, aniline point, basic
nitrogen, neutralization number, metals, and asphalt tests (e.g. penetration and softening
point).

It is assumed that the product from an oil well has the following composition and properties,
represented in an assay, determined by chromatography:

Table 1: Bulk properties of crude oil

Bulk properties Value

Molecular weight 79.6
Density 0.6659 SG_60/60 api
Bulk properties Value

142
 Table 2: Components and their fractions from a crude oil assay

Component type Name Mole %

Light components N2 0.48
H2S 0.00
CO2 0.87
C1 41.83
C2 8.87
C3 7.11
i - C4 3.75
i – C5 1.25
n – C5 1.63
C6 0.00
H20 0.00
Aromatic components Benzene (C6H6) 0.0004
Toluene (C7H8) 0.0015
EBZ, p+m Xylene (C8H10) 0.0070
o – Xylene (C8H10) 0.0028
1,2,4 TriMethylBenzene (C9H12) 0.0028
Naphthenic components Cyclopentane (C5H10) 0.0002
MethylCycloPentane (C6H12) 0.0106
Cyclohexane (C6H12) 0.0050
MethylCycloHexane (C7H14) 0.0150

143
 Table 3: Components and their fractions from a crude oil assay (contd.)

Component type Name Mole %

Paraffinic components Hexane (C6) 0.0268
Heptane (C7) 0.0371
Octane (C8) 0.0348
Nonane (C9) 0.0231
Decane (C10) 0.0240
Undecane (C11) 0.0183
Dodecane (C12) 0.0142
Tridecane (C13) 0.0141
Tetradecane (C14) 0.0113
Pentadecane (C15) 0.0099
Hexadecane (C16) 0.0074
Heptadecane (C17) 0.0082
Octadecane (C18) 0.0062
Nonadecane (C19) 0.0049
Eicosane (C20) 0.0046
Heneicosane (C21) 0.0039
Docosane (C22) 0.0036
Tricosane (C23) 0.0032
Tetracosane (C24) 0.0027
Pentacosane (C25) 0.0024
Hexacosane (C26) 0.0021
Heptacosane (C27) 0.0020
Octacosane (C28) 0.0018
Nonacosane (C29) 0.0016
Triconane Plus 0.0133

144
In order to complete the characterization of this crude oil, the following steps are to be
followed:

1. Click on the new case icon.

2. From the simulation basis manager, from the components tab, click on Add.
3. Add the light components from the components library.

4. From the fluid package tab, to add a fluid package to the current component list, click
Add.

145
5. Click on the Peng – Robinson property package.

6. Cross – out the fluid package dialogue box.

7. From the simulation basis manager, click on the Oil Manager tab.
8. Once in the oil manager tab, click on Enter Oil Environment.

146
9. In the assay tab, click on Add.

10. Set the bulk properties to Used.

147
11. Set the assay data type to Chromatograph. The option selected here depends on the user.

12. Set the light ends data type to Input Composition.

148
13. Select the light Ends option from the input data and the light ends basis to be Mole %.

14. Fill in the composition of the light ends.

149
15. Select the Paraffinic option from the input data and fill in their mole fractions.

16. Select the Aromatic option from the input data and fill in their mole fractions.

150
17. Select the Naphthenic option from the input data and fill in their mole fractions.

18. Select the Bulk Properties option from the input data and fill in the given data.
19. Then click on Calculate.

151
20. The dialogue box will appear as above if the assay was calculated successfully.

21. Cross – out the assay dialogue box, select the Cut/Blend tab from the oil characterization
dialogue box, then click Add.

152
22. Click on Add to add the available assay.

23. Click on the Cut Option Selection and select Auto Cut, so that HYSYS automatically
determines the cut points of each component in the crude oil.
24. Auto Cut is the default option, but it can be changed according to user preferences.

153
25. Once the blend has been calculated, the Tables tab will show the properties of the
different fractions in the crude oil.

26. From the Property Plot tab (next to the Tables tab), select the True Boiling Point (TBP)
option.

154
27. This gives the plot of the temperature versus the liquid volume percent of the components
of the crude oil during distillation.

28. Selecting the Distribution Plot tab shows the histogram of the liquid volume fraction of
the total oil that will be present within each boiling point range.

155
29. Selecting the Composite Plot tab shows the temperature versus the mole percent present
of the components in the chromatograph.

30. Cross – out the Blend dialogue box.

31. Select the Install Oil tab from the Oil Characterization dialogue box.
32. Give the stream a name, as shown above.
33. Click on Return to Basis Environment.

156
34. The crude oil stream will now be shown in the PFD with its stream name as depicted
above, ready for further simulation.

157
Side Operations of a Distillation Column

Oil characterization is an important precursor to simulating the separation of the various

components of crude oil. For example, the Gas Well 1 stream prepared previously could be
fed to a distillation column to separate methane and propane contained in it.

The steps are as follows:

1. Fill in the specifications of the stream as above.

158
2. The above specifications were used in the column.

3. Double-click on the column, then click on the Side Ops tab.

4. Select the Side Strippers option on the side to add a side stripper to the column.
5. Click on add.

159
6. Fill in the necessary details for the side stripper in the box. Remember to send the return
stream to a stage below the draw stage.
7. For steam stripping (unlike reboiled shown above), specify the stream for steam as well.
8. Click on Install.

9. Click on Run.
10. The dialogue box should appear as above if the side stripper has converged.

160
11. The product stream 3 shows it is rich in propane.

12. For the Side Rectifier, return to the Side Ops tab.
13. Select the Side Rectifier option.
14. Fill in the specifications as above. The return stream must be to a tray below the draw
stream.

*A side rectifier is best described as a distillation column having a feed which is side-drawn
from another column to obtain a fraction from the crude oil which would otherwise not be
possible.

161
15. The box for a side rectifier would look like the one above on converging.

16. The vapor product stream 4 contains mostly methane.

162
17. For the Pump Arounds, return to the Side Ops tab.
18. Select the Pump Arounds option.
19. Fill in the return and draw stages. In this case, the return stream should be sent to a tray
above the draw stream.

20. Double-click on the Flow and Duty parameters shown in black.

163
21. The 2 dialogue boxes shown above would appear, 1 for each of the parameters.
22. The Active Specs can be chosen other than Flow and Duty, and can be selected from the
drop down menu below Spec type.
23. Set the Spec Value for each parameter.

24. A properly specified pump around would have a box as shown above.

164
25. The associated side ops window would like the image above.

26. After completion, the distillation column with its side operations would look like the PFD
shown above.

165
27. To see which draw and return is from which stream, and the side operations in detail,
double-click on the distillation column.
28. Then click on Column Environment.

29. This would show the whole process in detail.

166
30. To go back to the parent environment, go to the menu bar.
31. Just below it, beside the conical flask for returning to the basis environment, is the arrow
shown above. Clicking on it will return the PFD to its normal form.

167